Multi-film thermoplastic structures having visually-distinct contact areas arranged in text and methods of making the same

ABSTRACT

One or more implementations of a multi-film thermoplastic structure include a first film having a first appearance in contact with a second film having a second appearance at one or more visually-distinct contact areas arranged into a text. Wherein the one or more visually-distinct contact areas, cause the first film to take on the second appearance of the second film. In one or more implementations the multi-film thermoplastic structure comprises a thermoplastic bag and text comprises a suffocation warning.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application is a continuation-in-part of U.S. patentapplication Ser. No. 17/167,390, filed on Feb. 4, 2021 and entitledMULTI-FILM THERMOPLASTIC BAGS HAVING GRAB ZONES WITH CONTACT AREAS ANDMETHODS OF MAKING THE SAME, which is a continuation-in-part ofInternational Application No. PCT/US2020/024143, filed on Mar. 23, 2020and entitled: MULTI-FILM THERMOPLASTIC STRUCTURES AND BAGS HAVINGVISUALLY-DISTINCT CONTACT AREAS AND METHODS OF MAKING THE SAME, whichclaims the benefit of and priority to U.S. Provisional Application No.62/825,520, filed Mar. 28, 2019 and entitled: MULTI-FILM THERMOPLASTICSTRUCTURES AND BAGS HAVING VISUALLY-DISTINCT CONTACT AREAS AND METHODSOF MAKING THE SAME. The contents of the above-referenced application arehereby incorporated by reference in their entirety.

BACKGROUND 1. Technical Field

The present application relates generally to thermoplastic bags. Moreparticularly, the present application relates to thermoplastic bagsincluding multiple films and unique aesthetics.

2. Background and Relevant Art

Thermoplastic films are a common component in various commercial andconsumer products. For example, grocery bags, trash bags, sacks, andpackaging materials are products that are commonly made fromthermoplastic films. Additionally, feminine hygiene products, babydiapers, adult incontinence products, and many other products includethermoplastic films to one extent or another.

With regard to bags made from thermoplastic films, some jurisdictionsrequire a suffocation warning on thermoplastic bags with openingsgreater than a predetermined size (e.g., 5 inches). Conventionally suchsuffocation warnings are printed on thermoplastic bags using ink. Forexample, a common technique is to print such warnings using a dot matrixtype ink jet printer. Unfortunately, such printed warnings often lackdensity and contrast, thereby reducing legibility. Furthermore, inkprinted on thermoplastic bags often lacks permanence. For example, theink may wipe off or smear due to contact, particularly when thethermoplastic film contains additives that migrate to the film surfaceand interfere with ink adhesion. In an attempt to avoid some of theforegoing problems, manufacturers may treat the surface of thermoplasticfilms. Ink printing on treated thermoplastic films, however, often stilllacks density, contrast, and permanence.

Additionally, printing ink on thermoplastic bags causes a decrease inefficiency and an increase in the cost of bag production. Both ink-basedprinting equipment and surface treating equipment is expensive and addsprocessing time. Furthermore, such equipment requires frequentmaintenance, which can temporarily halt bag production all together.

In addition to the foregoing, the cost to produce products includingthermoplastic film is directly related to the cost of the thermoplasticfilm. Recently the cost of thermoplastic materials has risen. Inresponse, some attempt to control manufacturing costs by decreasing theamount of thermoplastic material in a product. One way manufacturers mayattempt to reduce production costs is to stretch the thermoplastic film,thereby increasing its surface area and reducing the amount ofthermoplastic film needed to produce a product of a given size.

While stretched, thinner gauge materials can represent cost savings tothe manufacturer, the use of thinner gauge films can result in lowerdurability. Although some recent technology may, in some cases at least,result in relatively thinner gauge films that may be as strong as theirthicker counterparts, customers naturally sense from prior experiencethat thinner gauge materials are lower in quality and durability.

For example, some cues to a customer of lower quality and durability ofa film are how thick or thin the film feels and how thin or weak thefilm “looks.” Customers tend to view thin looking or feeling films ashaving relatively low strength. This is particularly true when thinlooking or feeling films are used in areas of customer products withwhich the customer comes in direct contact—such as the open end of atrash bag where a customer would gather the bag in order to remove thebag from a trash can.

Thus, even though some mechanisms can improve some aspects of filmstrength while using a thinner gauge, the look and feel of such filmstend to cause customers to believe the film is nevertheless low quality.For example, thinner thermoplastic films are typically more transparentor translucent. Such consumers may feel that they are receiving lessvalue for their money when purchasing products with thinner films; andthus, may be dissuaded to purchase thinner thermoplastic films.

BRIEF SUMMARY

One or more implementations of the present disclosure solve one or moreproblems in the art with multi-film thermoplastic structures includingtext formed by visually-distinct contact areas between adjacent films.The text comprises areas in which at least first and secondthermoplastic films of the multi-film thermoplastic structure are inintimate contact. Furthermore, when viewing the first thermoplasticfilm, the visually-distinct contact areas formed into text differ inappearance (e.g., have a different color) than areas of the firstthermoplastic film not in intimate contact with the second thermoplasticfilm. The difference in appearance between the text areas and theadjacent film provides contrast that results in enhanced legibility ofthe text as compared to ink-based text without the drawbacks of inkprinting.

For example, an implementation of a multi-film thermoplastic structurecomprises a first thermoplastic film having a first appearance and asecond thermoplastic film having a second appearance created by apigment. The first appearance differs from the second appearance. The amulti-film thermoplastic structure also includes one or more separatedportions where the first thermoplastic film and the second thermoplasticfilm are not in intimate contact. The multi-film thermoplastic structurefurther includes one or more contact areas arranged into text. The oneor more contact areas arranged into text comprise portion of themulti-film thermoplastic structure where the first thermoplastic filmand the second thermoplastic film are in intimate contact. The one ormore contact areas arranged into text also comprise a contrast relativeto separated portions surrounding the one or more contact areas, whichwhen viewed in the first thermoplastic film make the text legible.

Additionally, an implementation of a thermoplastic bag includes firstand second thermoplastic film sidewalls joined together along a firstside edge, an opposite second side edge, and a closed bottom edge. Thefirst and second thermoplastic film sidewalls comprise a first color.The thermoplastic bag additionally includes a layer of thermoplasticmaterial adjacent to at least a portion of the first thermoplastic filmsidewall. The layer of thermoplastic material comprises a second color.The thermoplastic bag further comprises one or more separated portionswhere the first thermoplastic film sidewall and layer of thermoplasticmaterial are separated by a gap. The thermoplastic bag further includesone or more contact areas arranged into text. The one or more contactareas arranged into text comprise portions in which the firstthermoplastic film sidewall and layer of thermoplastic material arebonded together. The one or more contact areas arranged into text alsocomprise the second color whereby the one or more contact areas arrangedinto text differ in appearance from separated portions surrounding theone or more contact areas making the text legible when viewed in thefirst thermoplastic film sidewall.

In addition to the foregoing, a method for making a thermoplastic baginvolves positioning a first thermoplastic film having a firstappearance over a second thermoplastic film having a second appearance.The second appearance of the second thermoplastic film differs from thefirst appearance of the first thermoplastic film. The method alsoinvolves passing the first thermoplastic film and the secondthermoplastic film together through a set of contact rollers. The set ofcontact rollers comprise a plurality of punch regions arranged in astring of text. Additionally, passing the first thermoplastic film andthe second thermoplastic film together through the set of contactrollers creates the string of text in the thermoplastic bag by bondingthe first and second thermoplastic films together in a plurality ofcontact areas that are visually-distinct from areas in which firstthermoplastic film and the second thermoplastic film are separated. Themethod also involves forming the first and second thermoplastic filmsinto a bag.

Passing the first thermoplastic film and the second thermoplastic filmbetween the set of contact rollers creates one or more visually-distinctcontact areas between a flat portion of the first thermoplastic film toa flat portion of the second thermoplastic film. The one or morevisually-distinct contact areas create one or more areas in the flatportion of the first thermoplastic film having the second appearance.The one or more visually-distinct contact areas being configured toseparate before the flat portion of the first thermoplastic film or theflat portion of the second thermoplastic film fails when subjected topeel forces.

Additional features and advantages of will be set forth in thedescription which follows, and in part will be obvious from thedescription, or may be learned by the practice of such exemplaryimplementations. The features and advantages of such implementations maybe realized and obtained by means of the instruments and combinationsparticularly pointed out in the appended claims. These and otherfeatures will become more fully apparent from the following descriptionand appended claims, or may be learned by the practice of such exemplaryimplementations as set forth hereinafter.

BRIEF DESCRIPTION OF THE DRAWINGS

In order to describe the manner in which the above recited and otheradvantages and features of the present disclosure can be obtained, amore particular description of the present disclosure briefly describedabove will be rendered by reference to specific implementations thereofwhich are illustrated in the appended drawings. It should be noted thatthe figures are not drawn to scale, and that elements of similarstructure or function are generally represented by like referencenumerals for illustrative purposes throughout the figures. Understandingthat these drawings depict only typical implementations of the presentdisclosure and are not therefore to be considered to be limiting of itsscope, the present disclosure will be described and explained withadditional specificity and detail through the use of the accompanyingdrawings in which:

FIG. 1A-1C show partial side cross-sectional views of films havingvarying numbers of layers according to one or more implementations ofthe present disclosure;

FIG. 2 shows a partial side cross-sectional view of a multi-filmthermoplastic structure having contact areas between first and secondthermoplastic films according to one or more implementations of thepresent disclosure;

FIG. 3A shows a set of contact rollers for forming contact areasaccording to one or more implementations of the present disclosure;

FIG. 3B shows a close up view of the set of contact rollers of FIG. 3Aaccording to one or more implementations of the present disclosure;

FIG. 3C shows a perspective view of another set of contact rollers forforming contact areas according to one or more implementations of thepresent disclosure;

FIG. 3D shows a perspective view of yet another set of contact rollersfor forming contact areas arranged in text according to one or moreimplementations of the present disclosure;

FIG. 4 shows a view of a portion of a multi-film thermoplastic structurehaving contact areas arranged in text created by a set of contactrollers according to one or more implementations of the presentdisclosure;

FIG. 5 shows a perspective view of a multi-film thermoplastic bagincluding contact areas arranged in text according to one or moreimplementations of the present disclosure;

FIG. 6A shows a front view of a multi-film thermoplastic bag includingcontact areas arranged in text according to one or more implementationsof the present disclosure;

FIG. 6B illustrates a cross-sectional view of the multi-filmthermoplastic bag of FIG. 6A according to one or more implementations ofthe present disclosure;

FIG. 6C shows a front view of an inside of the multi-film thermoplasticbag including contact areas arranged in text of FIG. 6A according to oneor more implementations of the present disclosure;

FIG. 7 shows a front view of another multi-film thermoplastic bagincluding contact areas arranged in text according to one or moreimplementations of the present disclosure;

FIG. 8 shows a front view of yet another multi-film thermoplastic bagincluding contact areas arranged in text according to one or moreimplementations of the present disclosure;

FIG. 9A shows a front view of a thermoplastic bag including an insertand contact areas between the insert and the thermoplastic bag arrangedin text according to one or more implementations of the presentdisclosure;

FIG. 9B illustrates a cross-sectional view of the thermoplastic bag ofFIG. 9A according to one or more implementations of the presentdisclosure;

FIG. 10 shows a chart illustrating levels of heat and pressure appliedduring the contact area creation process according to one or moreimplementations of the present disclosure; and

FIG. 11 illustrates a schematic diagram of a process of manufacturing athermoplastic bag with contact areas arranged in text in accordance withone or more implementations of the present disclosure.

DETAILED DESCRIPTION

One or more implementations of the present disclosure include apparatusand methods for creating multi-film thermoplastic film structures orbags with contact areas arranged in text. In particular, one or moreimplementations include a multi-film thermoplastic bag including regionsof contact areas, where the contact areas create easily legible andvisible text. The contact areas, thus, create visual and tactile cues ofstrength and quality in areas of the multi-film thermoplastic bags thatare highly visible. In one or more implementations, the contact areasarranged to form text allows for thermoplastic film products to includetext without the use of ink, which after lacks density, contrast, andpermanence when printed on thermoplastic products.

In particular, one or more implementations include a multi-filmthermoplastic bag having sidewalls comprising a first thermoplastic filmand an adjacent second thermoplastic film. The contact areas compriseportions of the first thermoplastic film that are in intimate contactwith portions of the second thermoplastic film and vice versa. In one ormore implementations, the contact areas are arranged to form text, suchas suffocation warnings, branding, or other messages. Along withproviding a readable text, the contact areas provide the thermoplasticbag with a stronger and/or more rigid feel—thus, giving a tactile cuethat the bag is less likely to rip, tear, or puncture when handled.

In one or more implementations, the contact areas of a multi-filmthermoplastic bag can bring a surface of a first thermoplastic film anda second thermoplastic film into intimate contact. In one or moreimplementations, the first thermoplastic film is an outer thermoplasticbag of a multi-layered thermoplastic bag and the second thermoplasticfilm is an inner thermoplastic bag of the multi-layered thermoplasticbag. In alternative implementations, the first thermoplastic film is asidewall of a single layer thermoplastic bag and the secondthermoplastic film is an insert.

Bringing the first and second thermoplastic films into direct contactcan cause an appearance change. In particular, in one or moreimplementations, when viewed from the first thermoplastic film side ofthe multi-film thermoplastic bag, the contact areas comprise a differentcolor than the portions of the first thermoplastic film not in intimatecontact with the second thermoplastic film (e.g., separated by an airgap or space).

Moreover, when films of a multi-film thermoplastic bag have differentappearances, due to the inclusion of a pigment or other coloring agent,the contact areas cause the appearance of areas of visual contrast inadjacent films. For example, in a two-film thermoplastic bag where thefirst thermoplastic film is a light color and the second thermoplasticfilm is a dark color, intimate contact between the two films cause awetting effect in an area of the first thermoplastic film. For instance,the intimate contact removes air from between portions of the two filmssuch that the color of the second thermoplastic film shows through thefirst thermoplastic film. Thus, in this example the contact areas causea dark area to appear in the lighter first thermoplastic film. Thus, thecontact areas can create intimate contact between a portion of a firstfilm and a portion of a second film causing the area of intimate contactto take on the visual characteristics of one of the films.Alternatively, the area of the intimate contact can take on a visualappearance that is a blending of the first and second films, or anappearance that is different from both the first and second films. Inany event, the contact areas can have a size and arrangement to formtext that contrasts in appearance from areas of the first thermoplasticfilm not in intimate contact with the second thermoplastic film.

One will appreciate in light of the disclosure here that portions of thefilms of a multi-film thermoplastic bag can be brought into intimatecontact with each other using various techniques. In particular, one ormore implementations involve utilizing heat and pressure on the films ofthe multi-film thermoplastic bag to bring the films together and createthe contact areas. Furthermore, one or more implementations involvecontrolling the amount of heat and pressure to tailor the properties ofthe areas forming the contact areas. For example, in one or moreimplementations enough heat and pressure are applied so as to bring thefilms into intimate contact but not so much as to degrade the strengthor otherwise weakening the films. For example, in one or moreimplementations a strength of the films in the contact areas is notsubstantially weakened. More particularly, in one or moreimplementations a transverse-direction tensile strength of the filmswith contact areas is not significantly lower than the areas of thefilms not including the contact areas. Still further, in one or moreimplementations, an impact strength (e.g., as measured by a dart droptest) of the films with contact areas is not significantly lower thanthe areas of the films not including the contact areas.

Additionally, one or more implementations involve controlling the amountof heat and pressure to tailor the properties of the films forming thecontact areas such that the films are in intimate contact but unbondedor lightly bonded. For example, one or more implementations provide forforming contact areas between adjacent films of a multi-filmthermoplastic bag that are relatively light such that forces acting onthe multi-film bag are first absorbed by breaking the bond(s) of thecontact areas rather than, or prior to, tearing or otherwise causing thefailure of any of the films of the multi-film bag when subjected to peelforces within a given range. Such implementations can provide an overallthinner film employing a reduced amount of raw material that nonethelesshas maintained or increased strength parameters. Alternatively, suchimplementations can use a given amount of raw material and provide afilm with increased strength parameters. For example, films includingcontact areas can have an increased resistance to tear propagation. Inparticular, a tear propagating across the film can be stopped orotherwise prohibited when running into a contact area.

In particular, the contact areas between adjacent layers of multi-filmbags in accordance with one or more implementations can act to firstabsorb forces via breaking prior to allowing those same forces to causefailure of the individual films of the multi-film bag when subjected topeel forces. Such action can provide increased strength to themulti-film thermoplastic bag. In one or more implementations, thecontact areas include a bond strength that is less than a weakest tearresistance of each of the individual films so as to cause the bonds ofthe contact areas to fail prior to failure of the films when subjectedto peel forces within a given range. Indeed, one or more implementationsinclude contact areas that release between films of a multi-filmthermoplastic bag prior to any localized tearing of the films of themulti-film thermoplastic bag.

Thus, in one or more implementations, the contact areas of a multi-filmthermoplastic bag can fail before either of the individual layersundergoes molecular-level deformation. For example, an applied straincan pull the contact areas apart prior to any molecular-leveldeformation (stretching, tearing, puncturing, etc.) of the individualfilm layers. In other words, the contact areas can provide lessresistive force to an applied strain than molecular-level deformation ofindividual films of the multi-film bag. Such a configuration of contactareas can provide increased strength properties to the multi-filmthermoplastic bag as compared to a monolayer film of equal thickness ora multi-film bag in which the plurality of layers are tightly bondedtogether (e.g., coextruded). As such, contact areas arranged into textare able to convey a message as well as provide strength benefits.

In one or more alternative implementations, the contact areas of amulti-film thermoplastic bag are formed with heat and pressure so as tocreate a permanent bond between the first and second thermoplasticlayers. In such implementations, the bond between the first and secondthermoplastic layers created by the contact areas can be inseparablewithout causing failure of one or more of the first and secondthermoplastic films. Contact areas with permanent bonds can ensure thattext formed by the contact areas does not lose visibility during use ofthe thermoplastic bag or structure.

Various implementations of multi-layer thermoplastic structures, such asmulti-layer thermoplastic bags, with contact areas arranged into textprovide various advantages over conventional structures and techniques.For example, the contact areas can provide a contrast (as describedabove) that provides enhanced legibility of the text compared toink-based text on thermoplastic films. In particular, contact areasarranged into text in accordance with one or more implementations areconfigured to have higher density and more solidly defined text comparedto ink-based printing, particularly dot matrix type ink jet printers.

Furthermore, in one or more implementations, the contact areas arrangedinto text provide increased permanence compared to ink-based printing oftext on thermoplastic films. In particular, text formed from contactareas in accordance with one or more implementations cannot be wiped offor smeared as often happens to ink-printed text on thermoplastic films.

Additionally, creating text via contact areas rather than ink can reducecapital costs due to removal of ink-based printing and/or surfacetreatment equipment. In addition to reducing capital costs, use ofcontact area based text instead of ink can reduce manufacturing costs.In particular, by eliminating ink material consumption and volatileorganic compound management associated with printing ink-based text onthermoplastic films by creating text via contact areas reduces the costto create thermoplastic bags with text. Along related lines, suchthermoplastic bags with text can be created more efficiently by creatingthe text using contact areas instead of ink as no refilling of ink wellsor management of ink-based equipment is necessary.

As used herein, the terms “lamination,” “laminate,” and “laminatedfilm,” refer to the process and resulting product made by bondingtogether two or more layers of film or other material. The term“bonding,” when used in reference to bonding of multiple layers of amulti-film bag, may be used interchangeably with “lamination” of thelayers. According to one or more implementations, adjacent films of amulti-film bag are laminated or bonded to one another.

The term laminate is also inclusive of coextruded multilayer filmscomprising one or more tie layers. As a verb, “laminate” means to affixor adhere (by means of, for example, adhesive bonding, pressure bonding,ultrasonic bonding, corona lamination, heat bonding, and the like) twoor more separately made film articles to one another so as to form amulti-film bag. As a noun, “laminate” means a product produced by theaffixing or adhering just described.

In one or more implementations, the contact areas between films of amulti-film bag may be continuous. As used herein, a “continuous” area ofcontact areas refers to one or more contact areas that are continuouslypositioned in an area, and arranged in the machine direction, in thetransverse direction, or in an angled direction.

In one or more implementations, the contact areas between films of amulti-film bag may be in a discrete or non-continuous pattern (i.e.,discontinuous or partially discontinuous). As used herein, a “discretepattern” of contact areas refers to a non-repeating pattern of patternelements in the machine direction, in the transverse direction, or in anangled direction.

In one or more implementations, the contact areas between films of amulti-film bag may be in a partially discontinuous pattern. As usedherein, a “partially discontinuous” pattern of contact areas refers topattern elements that are substantially continuous in the machinedirection or in the transverse direction, but not continuous in theother of the machine direction or the transverse direction. Alternately,a partially discontinuous pattern of contact areas refers to patternelements that are substantially continuous in the width of the articlebut not continuous in the height of the article, or substantiallycontinuous in the height of the article but not continuous in the widthof the article. Alternatively, a partially discontinuous pattern ofcontact areas refers to pattern elements that are substantiallycontinuous for a width and height that is less than the width and heightof the article. More particularly, a partially discontinuous pattern ofcontact areas refers to repeating pattern elements broken up byrepeating separated areas in either the machine direction, thetransverse direction, or both. Both partially discontinuous anddiscontinuous patterns are types of non-continuous heated pressurebonding (i.e., bonding that is not complete and continuous between twosurfaces).

One or more implementations involve bringing pigmented, lightlypigmented, and/or substantially un-pigmented thermoplastic films intointimate contact. As used herein, the term “substantially un-pigmented”refers to a thermoplastic ply or plies that are substantially free of asignificant amount of pigment such that the ply is substantiallytransparent or translucent. For example, a “substantially un-pigmented”film can have a pigment concentration (i.e., percent of totalcomposition of the film) that is between 0% by weight and 2% by weight.In some embodiments, a “substantially un-pigmented” film can have apigment concentration between about 0% by weight and about 1% by weight.In further embodiments, a “substantially un-pigmented” film can have apigment concentration between about 0% by weight and about 0.75% byweight. A substantially un-pigmented film can have a transparent ortranslucent appearance.

As used herein, the term “lightly pigmented” refers to a thermoplasticply or plies that are pigmented such that, when placed into intimatecontact with a pigmented film, an unexpected appearance is produced. Forexample, the unexpected appearance can be a “wetting” of a color of thepigmented film through the lightly pigmented film. Alternately, theunexpected appearance may be an effect that differs from an appearance(e.g., colors) of the individual films. If a film has too much pigment,when placed into intimate contact with another pigmented film, anunexpected appearance will not be produced. The amount of pigment in alightly pigmented film that will produce the unexpected appearance canbe dictated by the thickness of the film.

A pigmented film, in one or more implementations, can comprise a lightlypigmented film or a film with a greater percentage of pigment than alightly pigmented film. As mentioned above, in one or more embodiments,a first thermoplastic film is substantially un-pigmented or lightlypigmented and a second thermoplastic film is pigmented. Thus, in one ormore embodiments, the second thermoplastic layer has a greaterpercentage of pigment than the first thermoplastic layer. Alternatively,the first and second thermoplastic layers have the same percentage ofpigment but the first thermoplastic layer comprises a lighter pigmentthan a pigment of the second thermoplastic layer. In still furtherimplementations, the substantially un-pigmented or lightly pigmentedthermoplastic film comprises a greater percent weight of pigment thanthe pigmented thermoplastic film. Nonetheless, in such implementations,the un-pigmented or lightly pigmented thermoplastic film can be moretransparent or translucent film than the pigmented thermoplastic film.

As used herein, the term “pigment or pigments” are solids of an organicand inorganic nature which are defined as such when they are used withina system and incorporated into the thermoplastic film, absorbing part ofthe light and reflecting the complementary part thereof which forms thecolor of the thermoplastic ply. Representative, but not limiting,examples of suitable pigments include inorganic colored pigments such assuch as iron oxide, in all their shades of yellow, brown, red and black;and in all their physical forms and particle-size categories, chromiumoxide pigments, also co-precipitated with nickel and nickel titanates,blue and green pigments derived from copper phthalocyanine, alsochlorinated and brominated in the various alpha, beta and epsiloncrystalline forms, yellow pigments derived from lead sulphochromate,yellow pigments derived from lead bismuth vanadate, orange pigmentsderived from lead sulphochromate molybdate lead oxide, cadmium sulfide,cadmium selenide, lead chromate, zinc chromate, nickel titanate, and thelike. For the purposes of the present invention, the term “organicpigment” comprises also black pigments resulting from organic combustion(so-called “carbon black”). Organic colored pigments include yellowpigments of an organic nature based on arylamides, orange pigments of anorganic nature based on naphthol, orange pigments of an organic naturebased on diketo-pyrrolo-pyrole, red pigments based on manganese salts ofazo dyes, red pigments based on manganese salts of beta-oxynaphthoicacid, red organic quinacridone pigments, and red organic anthraquinonepigments. Organic colored pigments include azo and diazo pigments,phthalocyanines, quinacridone pigments, perylene pigments,isoindolinone, anthraquinones, thioindigo, solvent dyes and the like.

Pigments can be light reflecting (e.g., white pigments) or lightabsorbing (e.g., black pigments). Examples of pigments suitable for oneor more implementations include titanium dioxide, Antimony Oxide, ZincOxide, White Lead, Lithopone, Clay, Magnesium Silicate, Barytes (BaSO4),and Calcium Carbonate (CaCO3).

Film Materials

As an initial matter, the thermoplastic material of the films of one ormore implementations of the present disclosure may include thermoplasticpolyolefins, including polyethylene and copolymers thereof andpolypropylene and copolymers thereof. The olefin-based polymers mayinclude ethylene or propylene based polymers such as polyethylene,polypropylene, and copolymers such as ethylene vinyl acetate (EVA),ethylene methyl acrylate (EMA) and ethylene acrylic acid (EAA), orblends of such polyolefins.

Other examples of polymers suitable for use as films in accordance withthe present disclosure may include elastomeric polymers. Suitableelastomeric polymers may also be biodegradable or environmentallydegradable. Suitable elastomeric polymers for the film includepoly(ethylene-butene), poly(ethylene-hexene), poly(ethylene-octene),poly(ethylene-propylene), poly(styrene-butadiene-styrene),poly(styrene-isoprene-styrene), poly(styrene-ethylene-butylene-styrene),poly(ester-ether), poly(ether-amide), poly(ethylene-vinylacetate),poly(ethylene-methylacrylate), poly(ethylene-acrylic acid), orientedpoly(ethylene-terephthalate), poly(ethylene-butylacrylate),polyurethane, poly(ethylene-propylene-diene), ethylene-propylene rubber,nylon, etc.

Some of the examples and description herein below refer to films formedfrom linear low-density polyethylene. The term “linear low densitypolyethylene” (LLDPE) as used herein is defined to mean a copolymer ofethylene and a minor amount of an olefin containing 4 to 10 carbonatoms, having a density of from about 0.910 to about 0.930, and a meltindex (MI) of from about 0.5 to about 10. For example, some examplesherein use an octene comonomer, solution phase LLDPE (MI=1.1; ρ=0.920).Additionally, other examples use a gas phase LLDPE, which is a hexenegas phase LLDPE formulated with slip/AB (MI=1.0; ρ=0.920). Still furtherexamples use a gas phase LLDPE, which is a hexene gas phase LLDPEformulated with slip/AB (MI=1.0; ρ=0.926). One will appreciate that thepresent disclosure is not limited to LLDPE, and can include “highdensity polyethylene” (HDPE), “low density polyethylene” (LDPE), and“very low density polyethylene” (VLDPE). Indeed, films made from any ofthe previously mentioned thermoplastic materials or combinations thereofcan be suitable for use with the present disclosure.

Some implementations of the present disclosure may include any flexibleor pliable thermoplastic material that may be formed or drawn into a webor film. Furthermore, the thermoplastic materials may include a singlelayer or multiple layers. The thermoplastic material may be opaque,transparent, translucent, or tinted. Furthermore, the thermoplasticmaterial may be gas permeable or impermeable.

As used herein, the term “flexible” refers to materials that are capableof being flexed or bent, especially repeatedly, such that they arepliant and yieldable in response to externally applied forces.Accordingly, “flexible” is substantially opposite in meaning to theterms inflexible, rigid, or unyielding. Materials and bags that areflexible, therefore, may be altered in shape and structure toaccommodate external forces and to conform to the shape of objectsbrought into contact with them without losing their integrity. Inaccordance with further prior art materials, web materials are providedwhich exhibit an “elastic-like” behavior in the direction of appliedstrain without the use of added traditional elastic materials. As usedherein, the term “elastic-like” describes the behavior of web materialswhich when subjected to an applied strain, the web materials extend inthe direction of applied strain, and when the applied strain is releasedthe web materials return, to a degree, to their pre-strained condition.

As used herein, the term “substantially,” in reference to a givenparameter, property, or condition, means to a degree that one ofordinary skill in the art would understand that the given parameter,property, or condition is met within a degree of variance, such aswithin acceptable manufacturing tolerances. By way of example, dependingon the particular parameter, property, or condition that issubstantially met, the parameter, property, or condition may be at least70.0% met, at least 80.0%, at least 90% met, at least 95.0% met, atleast 99.0% met, or even at least 99.9% met.

Additional additives that may be included in one or more implementationsinclude slip agents, anti-block agents, voiding agents, or tackifiers.Additionally, one or more implementations of the present disclosureinclude films that are devoid of voiding agents. Some examples ofinorganic voiding agents, which may further provide odor control,include the following but are not limited to calcium carbonate,magnesium carbonate, barium carbonate, calcium sulfate, magnesiumsulfate, barium sulfate, calcium oxide, magnesium oxide, titanium oxide,zinc oxide, aluminum hydroxide, magnesium hydroxide, talc, clay, silica,alumina, mica, glass powder, starch, charcoal, zeolites, any combinationthereof, etc. Organic voiding agents, polymers that are immiscible inthe major polymer matrix, can also be used. For instance, polystyrenecan be used as a voiding agent in polyethylene and polypropylene films.

One of ordinary skill in the art will appreciate in view of the presentdisclosure that manufacturers may form the films or webs to be used withthe present disclosure using a wide variety of techniques. For example,a manufacturer can form precursor mix of the thermoplastic material andone or more additives. The manufacturer can then form the film(s) fromthe precursor mix using conventional flat or cast extrusion orco-extrusion to produce monolayer, bilayer, or multilayer films.Alternatively, a manufacturer can form the films using suitableprocesses, such as, a blown film process to produce monolayer, bilayer,or multilayer films. If desired for a given end use, the manufacturercan orient the films by trapped bubble, tenterframe, or other suitableprocess. Additionally, the manufacturer can optionally anneal the filmsthereafter.

An optional part of the film-making process is a procedure known as“orientation.” The orientation of a polymer is a reference to itsmolecular organization, i.e., the orientation of molecules relative toeach other. Similarly, the process of orientation is the process bywhich directionality (orientation) is imposed upon the polymericarrangements in the film. The process of orientation is employed toimpart desirable properties to films, including making cast filmstougher (higher tensile properties). Depending on whether the film ismade by casting as a flat film or by blowing as a tubular film, theorientation process can require different procedures. This is related tothe different physical characteristics possessed by films made byconventional film-making processes (e.g., casting and blowing).Generally, blown films tend to have greater stiffness and toughness. Bycontrast, cast films usually have the advantages of greater film clarityand uniformity of thickness and flatness, generally permitting use of awider range of polymers and producing a higher quality film.

When a film has been stretched in a single direction (mono-axialorientation), the resulting film can exhibit strength and stiffnessalong the direction of stretch, but can be weak in the other direction,i.e., across the stretch, often splitting when flexed or pulled. Toovercome this limitation, two-way or biaxial orientation can be employedto more evenly distribute the strength qualities of the film in twodirections. Most biaxial orientation processes use apparatus thatstretches the film sequentially, first in one direction and then in theother.

In one or more implementations, the films of the present disclosure areblown film, or cast film. Both a blown film and a cast film can beformed by extrusion. The extruder used can be a conventional one using adie, which will provide the desired gauge. Some useful extruders aredescribed in U.S. Pat. Nos. 4,814,135; 4,857,600; 5,076,988; 5,153,382;each of which are incorporated herein by reference in their entirety.Examples of various extruders, which can be used in producing the filmsto be used with the present disclosure, can be a single screw typemodified with a blown film die, an air ring, and continuous take offequipment.

In one or more implementations, a manufacturer can use multipleextruders to supply different melt streams, which a feed block can orderinto different channels of a multi-channel die. The multiple extruderscan allow a manufacturer to form a film with layers having differentcompositions. Such multi-film bag may later be provided with a complexstretch pattern to provide the benefits of the present disclosure.

In a blown film process, the die can be an upright cylinder with acircular opening. Rollers can pull molten thermoplastic material upwardaway from the die. An air-ring can cool the film as the film travelsupwards. An air outlet can force compressed air into the center of theextruded circular profile, creating a bubble. The air can expand theextruded circular cross section by a multiple of the die diameter. Thisratio is called the “blow-up ratio.” When using a blown film process,the manufacturer can collapse the film to double the plies of the film.Alternatively, the manufacturer can cut and fold the film, or cut andleave the film unfolded.

In any event, in one or more implementations, the extrusion process canorient the polymer chains of the blown film. The “orientation” of apolymer is a reference to its molecular organization, i.e., theorientation of molecules or polymer chains relative to each other. Inparticular, the extrusion process can cause the polymer chains of theblown film to be predominantly oriented in the machine direction. Theorientation of the polymer chains can result in an increased strength inthe direction of the orientation. As used herein predominately orientedin a particular direction means that the polymer chains are moreoriented in the particular direction than another direction. One willappreciate, however, that a film that is predominately oriented in aparticular direction can still include polymer chains oriented indirections other than the particular direction. Thus, in one or moreimplementations the initial or starting films (films before beingstretched or bonded or laminated in accordance with the principlesdescribed herein) can comprise a blown film that is predominatelyoriented in the machine direction.

The process of blowing up the tubular stock or bubble can further orientthe polymer chains of the blown film. In particular, the blow-up processcan cause the polymer chains of the blown film to be bi-axiallyoriented. Despite being bi-axially oriented, in one or moreimplementations the polymer chains of the blown film are predominantlyoriented in the machine direction (i.e., oriented more in the machinedirection than the transverse direction).

The films of one or more implementations of the present disclosure canhave a starting gauge between about 0.1 mils to about 20 mils, suitablyfrom about 0.2 mils to about 4 mils, suitably in the range of about 0.3mils to about 2 mils, suitably from about 0.6 mils to about 1.25 mils,suitably from about 0.9 mils to about 1.1 mils, suitably from about 0.3mils to about 0.7 mils, and suitably from about 0.4 mils and about 0.6mils. Additionally, the starting gauge of films of one or moreimplementations of the present disclosure may not be uniform. Thus, thestarting gauge of films of one or more implementations of the presentdisclosure may vary along the length and/or width of the film.

As described above, a multi-film thermoplastic bag includes a pluralityof thermoplastic films. Each individual film may itself include a singlelayer or multiple layers. In other words, the individual films of themulti-film bag may each themselves comprise a plurality of layers. Suchlayers may be significantly more tightly bonded together than thebonding (if any) of the contact areas. Both tight and relatively weakbonding can be accomplished by joining layers by mechanical pressure,joining layers with heat, joining with heat and pressure, joining layerswith adhesives, spread coating, extrusion coating, ultrasonic bonding,static bonding, cohesive bonding and combinations thereof. Adjacentsub-layers of an individual film may be coextruded. Co-extrusion resultsin tight bonding so that the bond strength is greater than the tearresistance of the resulting laminate (i.e., rather than allowingadjacent layers to be peeled apart through breakage of the laminationbonds, the film will tear).

A thermoplastic film can may include a one, two, three, or more layersof thermoplastic material. FIGS. 1A-1C are partial cross-sectional viewsof films that can be included in a multi-film thermoplastic bag of oneor more implementations. In some implementations, the film may include asingle layer film 102 a, as shown in FIG. 1A, comprising a single firstlayer 110. In other embodiments, the film can comprise a two-layer film102 b as shown in FIG. 1B, including the first layer 110 and a secondlayer 112. The first and second layers 110, 112 can be coextruded. Insuch implementations, the first and second layers 110, 112 mayoptionally include different grades of thermoplastic material and/orinclude different additives, including polymer additives and/orpigments. In yet other implementations, a film be a tri-layer film 102c, as shown in FIG. 1C, including the first layer 110, the second layer112, and a third layer 114. In yet other implementations, a film mayinclude more than three layers. The tri-layer film 102 c can include anA:B:C configuration in which all three layers vary in one or more ofgauge, composition, color, transparency, or other properties.Alternatively, the tri-layer film 102 c can comprise an A:A:B structureor A:B:A structure in which two layers have the same composition, color,transparency, or other properties. In an A:A:B structure or A:B:Astructure the A layers can comprise the same gauge or differing gauge.For example, in an A:A:B structure or A:B:A structure the film layerscan comprise layer ratios of 20:20:60, 40:40:20, 15:70:15, 33:34:33,20:60:20, 40:20:40, or other ratios.

In one example, the film 102 a can comprise a 0.5 mil, 0.920 densityLLDPE, colored film containing 4.8% pigment that appears a first color.In an alternative embodiment, the film 102 a can comprise a 0.5 mil,0.920 density LLDPE, un-pigmented film that appears clear orsubstantially clear. In still further embodiments, the film 102 a cancomprise a 0.5 mil, 0.920 density LLDPE, pigmented film that appears asecond color.

In at least one implementation, such as shown in FIG. 1C, a multilayeredfilm 102 c can include co-extruded layers. For example, the film 102 ccan include a three-layer B:A:B structure, where the ratio of layers canbe 20:60:20. The exterior B layers (i.e., the first layer 110, and thethird layer 114) can comprise a mixture of hexene LLDPE of density0.918, and metallocene LLDPE of density 0.920. The interior A core layer(i.e., the second layer 112) can comprise a mixture of hexene LLDPE ofdensity 0.918, butene LLDPE of density 0.918, reclaimed resin from trashbags. Additionally, the A core layer (i.e., the second layer 112) caninclude a pigment. For example, the A core layer can include a colorantin an amount between about 0.1 percent and about 6%.

In another example, the film 102 c is a coextruded three-layer B:A:Bstructure where the ratio of layers is 15:70:15. The B:A:B structure canalso optionally have a ratio of B:A that is greater than 20:60 or lessthan 15:70. In one or more implementations, the LLDPE can comprisegreater than 50% of the overall thermoplastic material in the film 102c.

In another example, the film 102 c is a coextruded three-layer C:A:Bstructure where the ratio of layers is 20:60:20. The C layer (i.e., thethird layer 114) can comprise a LLDPE material with a first colorant(e.g., black). The B layer (i.e., the second layer 112) can alsocomprise a LLDPE material with a second colorant (e.g., white). TheLLDPE material can have a MI of 1.0 and density of 0.920 g/cm3. The Acore layer (i.e., the first layer 110) can comprise similar materials toany of the core layer describe above. The A core layer can comprise ablack colorant, a white colorant, or can be clear.

In still further embodiments, a film can comprise any number ofco-extruded layers. More particularly in one or more embodiments, a filmcan comprise any number of co-extruded layers so long as the A and Blayers do not alternate such that the A layers are on one side and the Blayers are on the other side. In still further embodiments, a film cancomprise one or more co-extruded layers between the A and B layers. Forexample, the film can comprise clear or transparent layers between the Aand B layer(s). In still further embodiments, a film can compriseintermittent layers of different colors in addition to the A and Blayer(s).

FIG. 2 illustrates one example of a multi-film thermoplastic structure202 including contact areas 210 between a first thermoplastic film 204and a second thermoplastic film 206. Each of the thermoplastic films204, 206 can comprise any of the thermoplastic films 102 a-102 cdescribed above or a film with more than three layers. FIG. 2illustrates that the first thermoplastic film 204 of the multi-filmthermoplastic structure 202 abutted directly against the secondthermoplastic film 206 at contact areas 210. In particular, themulti-film thermoplastic structure 202 can include contact areas 210 andseparated areas 208. The contact areas 210 remove the air and/or spacebetween the thermoplastic films 204, 206.

As shown by FIG. 2 , the contact areas 210 can comprise areas in whichthe first thermoplastic film 204 is in direct, or intimate, contact withthe second thermoplastic film 206. As such, the contact areas 210 cancreate regions that are visually distinct from the rest of themulti-film thermoplastic structure 202 (at least when viewing the majorsurface of the first thermoplastic film 204). In other words, becausethe first thermoplastic film 204 is directly abutted against the secondthermoplastic film 206, the contact areas 210 can have the color orappearance of the second thermoplastic film 206 or another color orappearance that differs from the separated portions of the firstthermoplastic film 204.

For example, in one or more implementations, the second thermoplasticfilm 206 can comprise a pigmented film and have a black appearance whilethe first thermoplastic film 204 is substantially un-pigmented orlightly pigmented and have a clear, transparent, or cloudy appearance.When combined to form a multi-film thermoplastic structure 202 inaccordance the principles described herein, the first thermoplastic film204 as part of the multi-film thermoplastic structure 202 can have acolor or appearance that differs from the color of the firstthermoplastic film 204. For example, the first thermoplastic film 204can have a metallic, silvery metallic or light grey color rather than ablack appearance or color as would be expected (i.e., due to viewing thesecond thermoplastic film 206 through a clear or transparent film). Theregions or areas of the two films in intimate contact with each othercreate contact areas that have a color or appearance that differs fromthe color or appearance of the first thermoplastic film 204. Forexample, the contact areas 210 can have the color or appearance of thesecond thermoplastic film 206 (e.g., black).

In one or more alternative implementations, the first thermoplastic film204 comprises a light colorant while the second thermoplastic film 206comprises a dark colorant. As used herein, a light colorant is a colorwith a brightness closer to the brightness of white than the brightnessof black. As used herein, a dark colorant is a color with a brightnesscloser to the brightness of black than the brightness of white. In oneor more embodiments, the first thermoplastic film 204 has aconcentration of light colorant between about 1% by mass and about 15%by mass. More particularly, in one or more embodiments, the firstthermoplastic film 204 has a concentration of light colorant betweenabout 2% by mass and about 12% by mass. In still further embodiments,the first thermoplastic film 204 has a concentration of light colorantbetween about 5% by mass and about 10% by mass.

Still further, the second thermoplastic film 206 has a concentration ofdark colorant between about 1% by mass and about 15% by mass. Moreparticularly, in one or more embodiments, the second thermoplastic film206 has a concentration of dark colorant between about 2% by mass andabout 12% by mass. In still further embodiments, the secondthermoplastic film 206 has a concentration of dark colorant betweenabout 5% by mass and about 10% by mass.

The white colored first thermoplastic film 204, when part of themulti-film thermoplastic structure 202 can have a gray appearance. Theforegoing described color change may give the appearance of a thirdcolor without requiring the actual colorant mixture of the third colorto be within the multi-film thermoplastic structure 202. In other words,the bag can be devoid of a gray pigment. For example, it may allow afilm having a viewable black layer and a viewable white layer to have(i.e., mimic) a gray appearance (often a consumer preferred color).Furthermore, the foregoing described color change may allow the film tomimic a gray appearance without significantly increasing and/or reducinga transparency (i.e., light transmittance) of the film. In other words,the foregoing described color change may allow the multi-filmthermoplastic structure 202 to mimic a gray appearance withoutdetrimentally affecting an appearance of quality of the film.

Thus, the contact areas have a color or appearance that differs from thecolor or appearance of the first thermoplastic film 204. For example,the contact areas 210 can have the color or appearance of the secondthermoplastic film 206 (e.g., black) or another color. One willappreciate in light of the disclosure herein that black and white areused as exemplary colors for ease in explanation. In alternativeembodiments, the films can comprise other color combinations such aswhite and blue, yellow and blue, red and blue, etc.

Irrespective of the specific colors of the first and secondthermoplastic films, the contact areas 210 can have a substantial changein appearance compared to the separated areas 208 when viewed from thefirst thermoplastic film side of the multi-film thermoplastic structure202. In some embodiments, for example, when using the LAB color space, arepresents a measurement of green and magenta values, b represents ameasurement of blue and yellow values, and L represents a measurement oflightness (i.e., white and back values). In some embodiments, the changein appearance of the contact areas 210 comprises a color change in whichthe L value decreases by at least five points. In some embodiments, thechange in appearance of the contact areas 210 comprises a color changein which the L value decreases between five and forty points, betweenfive and thirty points, or between five and twenty points.

For example, the change in appearance of the contact areas 210 mayinclude a perceivable change of color from gray to black. In additionalembodiments, the change in appearance of the contact areas 210 mayinclude a perceivable change of color from a first relatively lightercolor to a second darker color. For example, the change in appearancemay include perceivable change of color from a first light gray to asecond dark gray. In other implementations, the change in appearance mayinclude perceivable change of color from a first lighter version of anycolor to a second darker version of the same color.

As another example, it may allow a film having a viewable blue layer(with a back yellow layer) to have (i.e., mimic) a green appearance.Furthermore, the foregoing described color change may allow the film tomimic a green appearance without significantly increasing and/orreducing a transparency (i.e., light transmittance) of the film. Inother words, the foregoing described color change may allow the film tomimic a green appearance without detrimentally affecting an appearanceof quality of the film. As a result of the foregoing, the multi-layerfilm of the present disclosure may provide a multi-layer film having aparticular appearance (e.g., a green appearance) while reducing costs.One will appreciate that other color combination in addition towhite/black producing grey and yellow/blue producing green are possibleand the foregoing are provided by way of example and not limitation.

FIG. 2 further illustrates that the contact areas 210 optionally securethe thermoplastic films 204, 206 of the multi-film thermoplasticstructure 202 such that the thickness of the thermoplastic films 204,206 is substantially unchanged at each of the contact areas 210. Inother words, each of the first and second thermoplastic films 204, 206can have a substantially uniform gauge (e.g., are substantially flat).In other words, the gauge of the first and second thermoplastic films204, 206 in the separated areas 208 is substantially the same as thegauge of the first and second thermoplastic films 204, 206 in thecontact areas 210. This is in contrast to ring rolled, SELF'ed,conventional embossing, or other processes that can bond film layerstogether, while also deforming portions of the films. As mentionedabove, the heat, pressure, and depth of engagement during creation ofthe contact areas can control to what extent, if any, the thermoplasticfilms are deformed when forming the contact areas 210. In one or moreimplementations, the process of forming the contact areas 210 does notdeform, or does not substantially deform, the thermoplastic films suchthat they are flat, or appear flat, despite the presence of contactareas 210. In alternative implementations, the portions of the first andsecond thermoplastic films comprising the contact areas 210 create anincrease or decrease in the gauge or loft of the multi-filmthermoplastic structure 202.

In one or more implementations, the creation of the contact areas 210does not weaken the first and second thermoplastic films 204, 206. Forexample, in one or more implementations, film strength in the portionsof the first and second thermoplastic films 204, 206 comprising thecontact areas 210 is not significantly lower than the portions of thefirst and second thermoplastic films 204, 206 in the areas 208 ofseparation. In particular, in one or more implementations, film in thecontact areas 210 have transverse direction tensile strength that is thesame as the film in the separated areas 208.

Moreover, the creation of the contact areas 210 can create other tactilefeatures in the multi-film thermoplastic structure 202. For example,regions of the multi-film thermoplastic structure 202 including thecontact areas 210 can have an increased rigidity over other regions ofthe multi-film thermoplastic structure 202 without contact areas. Insome implementations, the contact areas 210 may increase the rigidity ofthe multi-film thermoplastic structure 202 by a factor of one. In otherimplementations, the contact areas 210 may increase the rigidity of themulti-film thermoplastic structure 202 by as much as a factor of three.Alternatively, the contact areas 210 may not increase the rigidity ofthe multi-film thermoplastic structure 202 at all.

FIGS. 3A-3D illustrate various implementations of contact rollers forforming contact areas. For example, as shown in FIG. 3A, the contactrollers include a punch roll 302 and a cooperating die roll 304. Each ofthe punch roll 302 and the die roll 304 may be cylindrical and may havelongitudinal axes that are parallel to each other. The punch roll 302and the die roll 304 may define a passage or tooling nip therebetweenthrough which film materials may pass through to form the contact areas.As shown in FIG. 3A, the punch roll 302 is provided with punch elements308 that extend outward from a surface of the punch roll 302. The dieroll 304 is provided with corresponding die recesses 306 that extendinto the surface of the die roll 304 for cooperating with, or receiving,the punch elements 308.

As illustrated in the enlargement shown in FIG. 3B, the punch elements308 may each have a plurality of punch elements for cooperating withcorresponding die elements in the die recesses 306. The cooperatingengagement of the punch elements with the die elements, with one or morethermoplastic films therebetween, forms contact areas by pressingthermoplastic films together.

FIG. 3C illustrates an alternative set of contact rollers comprise apunch roll 302 and a press roll 310. The press roll 310 may comprise aconformable surface for conforming to the punch elements, or othersurface configuration of the punch roll 302. In still furtherembodiments, the press roll can comprise a rubber roll or roll formedform another conformable material.

FIG. 3D illustrates yet another implementation of contact rollersincluding a punch roll 302 a and a press roll 310. More particularly,the contact rollers of FIG. 3D are sized and configured to createcontact areas arranged in text in multi-film thermoplastic structures(e.g., thermoplastic bags). In particular, the punch roll 302 a includespunch elements 308 a sized and configured to create a first pattern ofcontact areas comprising text (i.e., a suffocation warning) in amulti-film thermoplastic structure. The punch roll 302 a furtherincludes punch elements 308 b sized and configured to create a secondpattern of contact areas (e.g., a plurality of diamond shaped contactareas). More specifically, as a multi-film thermoplastic structurecomprising a darker pigmented thermoplastic film and a lighter ornon-pigmented thermoplastic film passes between the contact rollers 302a, 310, the punch elements 308 a, 308 b of the punch roll 302 a pressesportions of the thermoplastic films together against the press roll 310.In one or more implementations the punch roller 302 a is metallic andheated. The heat and pressure supplied by the contact rollers 302 a, 310form contact areas in the multi-film thermoplastic structure have theshape of the punch elements 308 a, 308 b of the punch roll 302 a.

One of the rolls may be formed from a relatively hard material (e.g.,steel, aluminum, ebonite or other suitable hard material), and the othermay be formed from a softer material (e.g., rubber or other suitablesofter material). For example, the punch roll 302/302 a and thecooperating die roll 304 or press roll 310 may include a steel-to-rubberinterface. In alternative embodiments, both the punch roll 302/302 a andthe die/press roll 304/310 may be formed from the relatively hardmaterial (e.g., steel). Put another way, the punch roll 302/302 a andthe die/press roll 304/310 may include a steel-to-steel interface.Regardless of whether the punch roll 302/302 a and the die/press roll304/310 include a steel-to-rubber interface or a steel-to-steelinterface, in one or more implementations, one or more of the contactrollers may include an electrically heated roll (e.g., means ofheating). For example, in one embodiment, an aluminum punch roll 302 isinternally heated by an electric source and a rubber die/press roll304/310 is unheated. Alternatively, in at least one embodiment, at leastone of the punch roll 302/302 a and the die/press roll 304/310 may beexternally heated (e.g., by directing a heat source at one or more outerportions of the roll). In alternative embodiments, neither of thecontact rollers are heated.

The plurality of punch elements may have height of between about 10.0mils and about 150.0 mils, and the receiving the die elements may havedepth of between about 10.0 mils and about 120.0 mils. In at least oneimplementation, as shown in FIG. 3B, the punch elements and thecorrelating die elements can include a plurality of evenly spacedsquares forming a repeat unit. In alternative implementations, the punchelements and the correlating die elements can include a plurality ofevenly spaced chevron patterns. Alternatively, the punch elements andthe correlating die elements can include a plurality of random polygonshaped protrusions and a plurality of matching random polygon shapedrecesses to form a mosaic of random polygon shaped recesses.

In at least one embodiment, one or both of the contact rollers 302/302a, 304 and/or the press roll 310 (as shown in FIGS. 3A-3D above) areheated to a temperature between 125 degrees and 324 degrees (Fahrenheit)in order to create the contact areas. Additionally, in at least oneembodiment, the contact rollers 302/302 a, 304 and/or the press roll 310may create the contact areas by being positioned so as to create atooling nip (e.g., a passage) where a multi-film thermoplastic structurepassing therein experiences pressure within a range of 100-1800 poundsper square inch. Furthermore, the contact rollers 302/302 a, 304 and/orthe press roll 310 may create the contact areas by spinning at speeds of500-1200 feet per minute. In one or more embodiments, the contactrollers 302/302 a, 304 and/or 310 may operate within these ranges ofheat, pressure, and speed while processing a two-layer thermoplasticfilm, a four-layer thermoplastic film, an eight-layer thermoplasticfilm, or a multi-film thermoplastic structure with even more layers. Inat least one embodiment, one or both of the contact rollers 302/302 a,304 and/or the press roll 310 are pre-heated along the outer perimeterof the contact rollers 302/302 a, 304 and/or the press roll 310 to atemperature within the range described above. Additionally, oralternatively, the multi-film thermoplastic structure may be pre-heatedprior to passing through the contact rollers 302/302 a, 304 and/or thepress roll 310.

Referring to FIG. 4 , a multi-film thermoplastic structure 320 withcontact areas arranged in text is illustrated. The multi-filmthermoplastic structure 320 includes a first thermoplastic film 312having a first appearance and a second thermoplastic film 314 having asecond appearance. The first appearance is a first color due to a firstpigment in the first thermoplastic film 312. Alternatively, the firstappearance is a clear appearance due to a lack of pigment. The secondappearance is a second color due to a second pigment in the secondthermoplastic film 314. As shown in the implementation of FIG. 4 , thefirst color creating the first appearance is lighter color (e.g., white)and the second color creating the second appearance is a darker color(e.g., black).

As shown by FIG. 4 , when the first thermoplastic film 312 issuperimposed directly over the second thermoplastic film 314, one ormore separated portions 316 where the first thermoplastic film 312 andthe second thermoplastic film 314 are not in intimate contact but areseparated (e.g., by an air gap) have a third appearance differing fromthe first appearance and the second appearance. In particular, as shownby FIG. 4 , the separated portions or areas 316 when viewed from thefirst thermoplastic film 312 side of the multi-film thermoplasticstructure 320 have a third color that differs from the first and secondcolors. As discussed above, the separated portions or areas 316 whenviewed from the first thermoplastic film 312 side of the multi-filmthermoplastic structure 320 have the unexpected third appearance despitethe multi-film thermoplastic structure 320 being devoid of a pigment ofthe third color. FIG. 4 illustrates the separated portions or areas 316when viewed from the first thermoplastic film 312 side having a greycolor.

The multi-film thermoplastic structure 320 includes a first pattern ofcontact areas 318 a arranged in text (e.g., arranged to spell “GLAD”).The contact areas 318 a arranged in text are formed by a pair of contactrollers similar to the contact rollers 302 a, 310. The multi-filmthermoplastic structure 320 also includes a second plurality of contactareas 318 b arranged in a repeating diamond pattern and separated areas316 where the films of the multi-film thermoplastic structure 320 arenot in intimate contact.

As mentioned above, and as discussed further below, the contact areas318 a, 318 b provide a visual impression with significant contrast tothe multi-film thermoplastic structure 320. In particular, as shown, thecontrast allows the text spelling GLAD to be legible. In other words,the contrast of the contact areas 318 a relative to separated portions316 surrounding the one or more contact areas 318 a, when viewed in thefirst thermoplastic film 312, makes the text legible. Additionally, asmentioned above, the contact areas 318 a, 318 b can increase a rigidityof the multi-film thermoplastic bag—thereby creating a sturdier andstronger feel in the areas of the multi-film thermoplastic bag includingthe contact areas 318 a, 318 b. In any event, in one or moreimplementations, the contact areas 318 a arranged into text havephysical parameters that are substantially equal to physical parametersof the multi-film thermoplastic structure 320 in the one or moreseparated portions 316. For example, the tensile strength of the contactareas 318 a arranged into text can comprise the same or substantiallyequal value as the tensile strength of the separated portions 316.

The contact areas 318 a, 318 b comprise portions of the multi-filmthermoplastic structure 320 where the first thermoplastic film 312 andthe second thermoplastic film 314 are in intimate contact. Additionally,the contact areas 318 a, 318 b comprise the second appearance of thesecond thermoplastic film 314. In particular, as shown by FIG. 4 , thecontact areas 318 a, 318 b comprise the second color (i.e., black).

Furthermore, depending upon the heat and pressure used to form thecontact areas 318 a, 318 b, the contact areas 318 a, 318 b can formbonds between the first thermoplastic film 312 and the secondthermoplastic film 314. In one or more implementations, the bonds of theone or more contact areas 318 a arranged into text are configured toseparate before either of the first thermoplastic film 312 or the secondthermoplastic film 314 fails when subjected to peel forces or forcesconsistent with use of a trash bag (e.g., loading the trash bag,removing the trash bag from a bin, or carrying a trash bag full oftrash). In other words, the bonds of the contact areas 318 a can beconfigured to have a weak bond strength as described above. Inalternative implementations, the bonds of the contact areas 318 aarranged into text are not configured to separate before either of thefirst thermoplastic film 312 or the second thermoplastic film 314 failswhen subjected to peel forces. In other words, the bonds can have astrong bond strength or be permanent bonds.

FIG. 5 is a perspective view of a multi-film thermoplastic bag 400including contact areas arranged into text according to animplementation of the present disclosure. The multi-film thermoplasticbag 400 includes a first sidewall 402 and a second sidewall 404. Each ofthe first and second sidewalls 402, 404 includes a first side edge 406,a second opposite side edge 408, a bottom edge 410 extending between thefirst and second side edges 406, 408. Each of the first and secondsidewalls 402, 404 also includes a top edge 411 extending between thefirst and second side edges 406, 408 opposite the bottom edge 410. Insome implementations, the first sidewall 402 and the second sidewall 404are joined together along the first side edges 406, the second oppositeside edges 408, and the bottom edges 410. The first and second sidewalls402, 404 may be joined along the first and second side edges 406, 408and bottom edges 410 by any suitable process such as, for example, aheated pressure seal. In alternative implementations, the first andsecond sidewalls 402, 404 may not be joined along the side edges.Rather, the first and second sidewalls 402, 404 may be a single uniformpiece. In other words, the first and second sidewalls 402, 404 may forma sleeve or a balloon structure.

In some implementations, the bottom edge 410 or one or more of the sideedges 406, 408 can comprise a fold. In other words, the first and secondsidewalls 402, 404 may comprise a single unitary piece of material. Thetop edges 411 of the first and second sidewalls 402, 404 may define anopening 412 to an interior of the multi-film thermoplastic bag 400. Inother words, the opening 412 may be oriented opposite the bottom edge410 of the multi-film thermoplastic bag 400. Furthermore, when placed ina trash receptacle (e.g., trash can), the top edges 411 of the first andsecond sidewalls 402, 404 may be folded over the rim of the receptacle.

In some implementations, the multi-film thermoplastic bag 400 mayoptionally include a closure mechanism located adjacent to the top edges411 for sealing the top of the multi-film thermoplastic bag 400 to forman at least substantially fully-enclosed container or vessel. As shownin FIG. 5 , in some implementations, the closure mechanism comprises adraw tape 416, a first hem seal 418, and a second hem seal 420. Inparticular, the first top edge 411 of the first sidewall 402 may befolded over into the interior volume and may be attached or secured toan interior surface of the first sidewall 402 by first hem seal 418.Similarly, the second top edge 411 of the second sidewall 404 is foldedover into the interior volume and may be attached to an interior surfaceof the second sidewall 404 by a second hem seal 420. The draw tape 416extends through hem channels created by the first and second hem seals418, 420 along the first and second top edges 411. The hem channelcreated by the first hem seal 418 includes a first aperture 424 (e.g.,notch) extending through the hem channel and exposing a portion of thedraw tape 416. Similarly, the hem channel created by the second hem seal420 includes a second aperture 422 extending through the hem channel andexposing another portion of the draw tape 416. During use, pulling thedraw tape 416 through the first and second apertures 422, 424 will causethe top edges 411 to constrict. As a result, pulling the draw tape 416through the first and second apertures 422, 424 will cause the opening412 of the multi-film thermoplastic bag 400 to at least partially closeor reduce in size. The draw tape closure mechanism may be used with anyof the implementations of a multi-film thermoplastic bag describedherein.

Although the multi-film thermoplastic bag 400 is described herein asincluding a draw tape closure mechanism, one of ordinary skill in theart will readily recognize that other closure mechanisms may beimplemented into the multi-film thermoplastic bag 400. For example, insome implementations, the closure mechanism may include one or more offlaps, adhesive tapes, a tuck and fold closure, an interlocking closure,a slider closure, a zipper closure, or any other closure structuresknown to those skilled in the art for closing a bag.

Each of the sidewalls 402, 404 of the multi-film thermoplastic bag 400comprise a multi-film thermoplastic structure, such as that shown inFIG. 2 above. Thus, each sidewall 402, 404 includes at least an innerlayer and an outer layer. Indeed, the thermoplastic bag 400 has abag-in-bag structure. In other words, the thermoplastic bag 400 includesa first bag and a second bag positioned therein. More particularly, thefirst thermoplastic bag comprises first and second opposing sidewallsjoined together along a first side edge, an opposite second side edge,and a closed first bottom edge. The second thermoplastic bag ispositioned within the first thermoplastic bag. The second thermoplasticbag comprises third and fourth opposing sidewalls joined together alonga third side edge, an opposite fourth side edge, and a closed secondbottom edge. In one or more implementations, the first thermoplastic bag(e.g., the outer layer) is pigmented with a first color, and the secondthermoplastic bag is pigmented with a second color (e.g., the innerlayer is pigmented with the second color). As described above, thediffering colors of the layers can allow for the creation of contactareas when the inner bag and the outer bag are placed into intimatecontact.

As shown in FIG. 5 , the multi-film thermoplastic bag 400 includes afirst region or grab zone 426 a, a second region 426 b, and a thirdregion 426 c. In the implementation shown, the first region 426 aincludes a pattern of contact areas 427. The pattern of contact areas427 shown in FIG. 5 includes a medium pattern density and exists on theouter and inner surfaces of the first and second sidewalls 402, 404.Additionally, the first region 426 a covers a portion of the multi-filmthermoplastic bag 400 extending from the first hem seal 418 toward thebottom edge 410 of the multi-film thermoplastic bag 400. Additionally,the pattern of contact areas 427 is registered to the same location onthe second sidewall 404 of the multi-film thermoplastic bag 400. Thethird region 426 c of the multi-film thermoplastic bag 400 is a flatportion of the multi-film thermoplastic bag 400.

In one or more implementations, the second region 426 b includes apattern of deformations including at least one of raised rib-likeelements in a strainable network or alternating thicker ribs and thinnerstretched webs (e.g., SELF'ed or ring rolled patterns). For example, asshown in FIG. 5 , the second region 426 b includes a checkerboardpattern of SELF'ed squares as described in International PatentApplication No. PCT/US2018/058998 filed on May 16, 2019 and entitled“THERMOPLASTIC FILMS AND BAGS WITH COMPLEX STRETCH PATTERNS AND METHODSOF MAKING THE SAME,” hereby incorporated by reference in its entirety.

As shown by FIG. 5 , the checkerboard pattern of deformations cancomprise a repeating pattern of raised rib-like elements. In particular,the checkerboard pattern of deformations can include a first pluralityof rib-like elements arranged pattern. Portions of the raised rib-likeelements of the outer layer can be in direct contact and have theappearance of the inner of the bag 400. In contrast to the pattern ofcontact areas 427, however, the portions of deformations (e.g., raisedrib-like element of a SELFing pattern or alternating thicker ribs andthinner stretched webs of a ring rolling pattern) stretch the filmincrementally to create areas of varying gauge or thickness.

As shown in FIG. 5 , the multi-film thermoplastic bag 400 includes asecond pattern of contact areas 428 forming dashed circles and a thirdpattern of contact areas 430 forming the text “GLAD.” The contact areas428/430 are formed over the checkerboard pattern of deformations. Inother words, the contact areas 428/430 can smash the deformations toform contact areas that contrast with the surrounding portions of thesidewall so the text is visible and legible.

The thermoplastic bag 400, as shown, includes side heat seals along theside edges 406, 408. As shown, the side heat seals can comprise areas inwhich all four or more layers of the thermoplastic bag are in intimatecontact. As such, the side heat seal (and any other heat seals such as ahem seal) can have the same appearance as the contact areas.

As shown by FIG. 5 , the contact areas in the grab zone 426 a form adiamond pattern 427 that provides the grab zone 426 a with a uniquevisual appearance that connotes strength. Additionally, as mentionedabove, the contact areas in the grab zone 426 a can provide increasedstiffness and other tactile cues that connote strength. As such, thecontact areas can provide the grab zone with both a look and feel ofincreased strength.

While FIG. 5 illustrates a pattern of contact areas 427 comprisingrepeating diamond-shaped elements, other implementations can comprisedifferently shaped contact areas. For example, the contact areas cancomprise squares, circles, ovals, stars, hexagons, or other shapes. Assuch, the use of diamond-shaped contact areas is for illustrativepurpose and does not limit the implementations of the present invention.

FIG. 6A illustrates a front view of a multi-film thermoplastic bag 600including contact areas arranged into text. The multi-film thermoplasticbag 600 can include many of the same features as the thermoplastic bag400 described above. The feature of the multi-film thermoplastic bag 600that are similar to the thermoplastic bag 400 include the same referencenumerals.

As shown in FIG. 6A, the multi-film thermoplastic bag 600 includes afirst region or grab zone 426 a, a second region 426 b, and a thirdregion 426 c. In the implementation shown, the first region 426 aincludes a pattern of contact areas 427. The pattern of contact areas427 shown in FIG. 6A includes a medium pattern density and exists on theouter and inner surfaces of the first and second sidewalls 402, 404where the individual contact areas are shaped as diamonds. Additionally,the first region 426 a covers a portion of the multi-film thermoplasticbag 600 extending from the bottom of the hem channel toward the bottomedge 410 of the multi-layer thermoplastic bag 600. Additionally, thepattern of contact areas 427 is registered to the same location on thesecond sidewall 404 of the multi-layer thermoplastic bag 600. The thirdregion 426 c of the multi-film thermoplastic bag 600 is a flat portionof the multi-layer thermoplastic bag 600.

Additionally, as shown by FIG. 6A, the multi-film thermoplastic bag 600includes a second plurality of contact areas 440 arranged into text. Inparticular, the second plurality of contact areas 440 arranged into textform a phrase comprising a suffocation warning. As shown, the secondplurality of contact areas 440 arranged into text extend across a widthof the multi-film thermoplastic bag 600 from the first side edge 406toward the opposite second side edge 408.

In one or more implementations the contact rollers used to form thecontact areas arranged into text can comprise phased rollers asdescribed in International Patent Application No. PCT/US2020/015580filed on Jan. 29, 2020 and entitled “THERMOPLASTIC BAGS WITH PHASEDDEFORMATION PATTERNS, hereby incorporated by reference in its entirety.For example, one or more implementations involve forming bags usingtooling phased relative to a width or height of the thermoplastic bags.More specifically, the tooling (i.e., contact rollers) is sized andconfigured such that one revolution (or fraction thereof) equals thewidth or height of a thermoplastic bag. In this manner, the tooling canbe configured to generate contact areas arranged into a phrase of text(e.g., a suffocation warning) that is included in its entirety on eachbag. In other words, the start and end of the phrase created by thecontact areas arranged into text is configured to start and end withinthe dimensions of each bag. This, as shown in FIG. 6A, the entiremessage can be less than the width (or height) of the bag therebyensuring that the entire message is present on a given bag and is notstraddle across multiple bags.

FIG. 6B illustrates a cross-sectional view of one or moreimplementations of the multi-film thermoplastic bag 600 shown in FIG.6A. For example, as shown in FIG. 6B, the multi-film thermoplastic bag600 includes an outer first thermoplastic bag 432 and an inner secondthermoplastic bag 434 positioned within the first thermoplastic bag 432.The top edges of the first thermoplastic bag 432 and the secondthermoplastic bag 434 are folded over the draw tape 416 to form a hemchannel 436. In one or more implementations, the draw tape 416 ismovable in the hem channel 436 so as to cinch the multi-filmthermoplastic bag 600 closed when pulled through the draw tapeapertures. In the embodiment illustrated in FIG. 6B, the hem channel 436is secured or held in place by a hem seal made up of the contact areas427, 440. In particular, the hem seal of contact areas 427, 440comprises a seal formed in a single operation (e.g., layers of thethermoplastic bag 600) through the contact rollers 310, 302 a describedabove in relation to FIG. 3D. In contrast to the hem seal 418, the hemseal of contact areas 427, 440 is formed by contact rollers rather thana seal bar. The hem seal of contact areas 427, 440 secures the hemchannel 436. In particular, the hem seal of contact areas 427, 440secure the hem skirt 438 to the inner second thermoplastic bag 434.Optionally, the hem seal of contact areas 427, 440 secures the outerfirst thermoplastic bag 432, the inner second thermoplastic bag 434, andthe layers of the hem skirt 438 together. Referring to FIG. 6A, the hemseal of contact areas 427, 440 comprises the contact areas in the firstregion 426 a. The hem seal of contact areas 427, 440 is a single seal inthat it is formed in a single operation despite the presence ofdifferent zones of contact areas (e.g., contact areas 427, followed bycontact areas 440, followed by contact areas 427).

As discussed above, the sidewalls of the multi-film thermoplastic bag600 can include the first region 426 a, the second region 426 b, and thethird region 426 c, where each region includes different bonding, or nobonding, between the first thermoplastic bag 432 and the secondthermoplastic bag 434. For example, as shown in FIG. 6B, the firstregion 426 a includes contact areas 427, 440 between the firstthermoplastic bag 432 and the second thermoplastic bag 434 where thefirst thermoplastic bag 432 and the second thermoplastic bag 434 havebeen brought into intimate contact via any of the processes describedabove, while leaving the thickness of the bags 432, 434 substantiallyunchanged in the first region 426 a. The second region 426 b includesareas of a plurality of deformations, where the plurality ofdeformations includes alternating thicker ribs and thinner stretchedwebs between the first and second bags 432, 434. The third region 426 cincludes an area that is flat and undeformed between the first andsecond bags 432, 434.

As further shown in FIG. 6B, folding over the top edges of the first andsecond bags 432, 434 creates a hem skirt 438 extending from the hemseals 418, 420 down an inner surface of the second thermoplastic bag434. As shown, the hem skirt 438 includes portions of the first andsecond bags 432, 434 that are the same length, where the length(distance from the hem channel toward the bottom of the bag) of the hemskirt 438. The hem skirt 438 may have a length of in a first range ofabout 0.1 inch (0.254 cm) to about 10 inches (25.4 cm), a second rangeof about 0.5 inches (1.27 cm) to about 8 inches (20.3 cm), a third rangeof about 1 inches (2.54 cm) to about 6 inches (15.2 cm), a fourth rangeof about 3 inches (7.6 cm) to about 6 inches (15.2 cm). In one or moreimplementations, the hem skirt 438 has a length of 0.5 inches (1.27 cm).In another implementation, the hem skirt 438 has a length of 4 inches(10.2 cm). In one implementation, the hem skirt 438 has a length of 5inches (12.7 cm). In another implementation, the hem skirt 438 has alength that is shorter or longer than the examples listed above.

The grab zone or first region 426 a may have a length (distance the grabzone extends from the hem channel toward the bottom of the bag) of about1 inch (2.54 cm) to about 10 inches (25.4 cm), a second range of about 3inches (7.6 cm) to about 8 inches (20.3 cm), a third range of about 4inches (10.2 cm) to about 6 inches (15.2 cm), a fourth range of about 3inches (7.6 cm) to about 6 inches (15.2 cm). In one implementation, thegrab zone has a length of 5 inches (12.7 cm). In a furtherimplementation, the grab zone has a length of 4 inches (10.2 cm). Inanother implementation, the grab zone has a length that is shorter orlonger than the examples listed above.

Furthermore, the hem skirt 438 can have a length that is co-extensive orthe same length as the grab zone 426 a. Alternatively, the hem skirt 438has a length less than a length of the grab zone 426 a. For example,FIG. 6B illustrates that the hem skirt 438 has a length approximately66% of the length of the grab zone 426 a. In alternativeimplementations, the hem skirt 438 has a length approximately 10%, 20%25% 33%, 50%, 75%, 80% or 90% of the length of the grab zone 426 a. Inanother implementation, the hem skirt 438 has a length that isrelatively shorter or longer than the examples listed above compared tothe grab zone 426 a. For example, in one or more implementations, thehem skirt 438 is longer than the grab zone 426 a.

As further shown in FIG. 6B, the contact areas 427, 440 in the firstregion 426 a extends through the hem skirt 438. For example, in at leastone implementation, the contact areas 427, 440 in the first region 426 aare formed after the top edges of the first and second bags 432, 434 arefolded over and secured via the hem seals 418, 420. Thus, the processthat forms the contact area 427, 440 (e.g., via the contact rollers 302,304 and/or the press roll 310 shown in FIGS. 3A-3D above) also formscontact areas 427, 440 between the first and second bags 432, 434 in thehem skirt 438, and contact areas 427, 440 between the sidewalls of thebag 400 and the hem skirt 438. The contact areas 427, 440 in the hemskirt 438 in combination with the contact areas 427 in the outer portionof the multi-film thermoplastic bag 600 can create rigidity in themulti-film thermoplastic bag 600 in the grab zone that is 0-3 greaterthan the rigidity of the multi-film thermoplastic bag 600 in the otherregions.

The portions of the first and second bags 432, 434 forming the hemskirts can be the same length or different lengths. For example, the topedge of the outer first thermoplastic bag 432 can extend a greaterlength in the hem skirt 438 than the top edge of the inner secondthermoplastic bag 434. In some implementations, the longer edge of thefirst thermoplastic bag 432 may be unattached from the inner surface ofthe second thermoplastic bag 434 by contact areas. In otherimplementations, the longer edge of the first thermoplastic bag 432 maybe in contact with the inner surface of the second thermoplastic bag 434via one or more contact areas, or another type of lamination.

The number of films (e.g., layers) that the contact areas 427, 440 bondtogether can vary in different implementations. For example, the contactareas 427, 440 can secure two layers (e.g., the two films of thesidewall), the contact areas 427, 440 can secure three layers (e.g., thetwo films of the sidewall and one of the films extending along theinside of the sidewall), or the contact areas 427, 440 can secure fourlayers (e.g., the two films of the sidewall and both of the filmsextending along the inside of the sidewall). The more layers bonded bythe contact areas 427, 440, the greater the stiffness and reinforcement.

In yet another implementation, the top edge of the inner secondthermoplastic bag 434 may extend beyond the top edge of the outer firstthermoplastic bag 432. For example, the top edge of the inner secondthermoplastic bag 434 may extend any distance beyond the top edge of theouter first thermoplastic bag 432. In another implementation, the hemskirt 438 may only include either the top edge of the outer firstthermoplastic bag 432 or the top edge of the inner second thermoplasticbag 434. In that implementation the hem skirt 438 may include contactareas 427, 440 between either the top edge of the outer firstthermoplastic bag 432 or the top edge of the inner second thermoplasticbag 434 and the inner surface of the inner second thermoplastic bag 434.Accordingly, the contact areas 427, 440 can be between two, three, orfour layers of the multi-film thermoplastic bag 600.

FIG. 6C illustrates an inside of the multi-film thermoplastic bag 600.In other words, FIG. 6C illustrates a view looking from the inside ofthe multi-film thermoplastic bag 600 toward the inner surface of theinner second thermoplastic bag 434. In the implementation of multi-filmthermoplastic bag 600 shown in FIGS. 6A-6C, the outer firstthermoplastic bag 432 (or outer film of the sidewall) has a first color(e.g., a lighter color). The inner second thermoplastic bag 434 (orinner film of the sidewall) has a second color (e.g., a darker color).As described above in relation to FIG. 4 , this allows the multi-filmthermoplastic bag 600 to have contact areas 440 formed or arranged intotext that differ in appearance from separated portions (areas in whichthe inner second thermoplastic bag 434 is not in intimate contact withthe outer first thermoplastic bag 432) surrounding the contact areas 440making the text legible when viewed in the outer first thermoplastic bag432 as shown in FIG. 6A. As shown in FIG. 6C, however, the multi-filmthermoplastic bag 600 is configured to reduce legibility of the textcreated by the contact areas 440 when viewed from an inside of themulti-film thermoplastic bag 600. In particular, in the implementationshown in FIG. 6C, the hem skirt 438 ends above the contact areas 440. Asshown when viewing the text created by the contact areas 440 in thesecond thermoplastic bag 434 (or inner film of the sidewall) due to thedarker color of the second thermoplastic bag 434 the text has reducedvisibility and legibility. Because the text is reversed when viewed inthe second thermoplastic bag 434 (or inner film of the sidewall), thereduced legibility of the text can reduce confusion.

While multi-film thermoplastic bags 400 and 600 described above eachincluded contact areas formed into text that extend along the width ofthe bags, alternative implementations include text formed by contactareas that extend vertically or diagonally. For example, FIG. 7illustrates a front view of a multi-film thermoplastic bag 700 thatincludes a first plurality of contact areas 702 arranged into text thatextend vertically adjacent to the first side edge 406 and side heat seal704 from the proximate the bottom edge 410 to just below the hem seal418. Furthermore, the multi-film thermoplastic bag 700 that includes asecond plurality of contact areas 706 arranged into text that extendvertically adjacent to the second side edge 408 and side heat seal 710from the just below the hem seal 418 to the bottom edge 410. As shown inFIG. 7 both the first plurality of contact areas 702 and the secondplurality of contact areas 706 are arranged into text including asuffocation warning.

In one or more implementations, one or more contact areas other thancontact areas arranged into text can be positioned in various portionsof a multi-film thermoplastic bag 700. FIG. 7 illustrates regions ofcontact areas. The regions of contact areas reduce puncturing andtearing in association with a grab zone of the multi-film thermoplasticbag. Moreover, the regions of contact areas provide increased stiffnessas well as other tactile cues connoting strength. As such, the grabzones of contact areas illustrated in provide both the look and feel ofincreased strength in areas of the multi-film thermoplastic bag mostlikely to be handled by a user.

For example, as shown in FIG. 7 , the multi-film thermoplastic bag 700includes a first region 712 of contact areas 713 extending from the hemseal 418. The contact areas 713 comprise diamond shapes and arepositioned within a grab zone.

A second region 714 includes a plurality of deformations 715 (e.g.,formed by SELFing). As shown, the second region 714 includes a patternof deformations 715 that includes diamonds and wavy lines. Additionally,the pattern of elements can take up any percentage of the second region714. For example, the pattern of elements in the second region 714 canbe a SELF'ing or ring rolling pattern. In particular, the second region714 includes a SELFing pattern of bulbous areas with nested diamonds.Wavy land areas separate the SELFing patterns. In some implementations,the wavy land areas may be contact areas in addition to the contactareas in the first region 712. In particular, the techniques describedin International Patent Application No. PCT/US2018/058998 filed on May16, 2019 and entitled “THERMOPLASTIC FILMS AND BAGS WITH COMPLEX STRETCHPATTERNS AND METHODS OF MAKING THE SAME,” hereby incorporated byreference in its entirety.

The multi-film thermoplastic bag 700 also includes the third region 716including a second pattern of contact areas 717. In the implementationshown, the first region of contact areas may function as a “grab zone,”while the third region 716 of contact areas may function asreinforcement for the bottom of the multi-film thermoplastic bag 700.The contact areas 717 include linear contact areas forming a repeatingpattern.

In one or more implementations, a multi-film thermoplastic bag caninclude multiple areas of contact areas in various patterns andlocations. For example, FIG. 8 shows the multi-film thermoplastic bag700 a with a first region 712 of contact areas 713 extending from thehem seal 418. The contact areas 713 comprise diamond shapes and arepositioned within a grab zone. A second region 714 includes contactareas 717 in a second pattern extending from the first region 712. Inone or more implementations, the contact areas 713 may serve to increasethe tactile cues of strength and durability (as they are positionedwithin the grab zone), while the contact areas 717 may serve to increasethe visual cues of strength and durability. As shown, the multi-filmthermoplastic bag 700 a in FIG. 8 includes a third region 716 ofdeformations 715, as discussed above, and a fourth region 726 of flatand undeformed film adjacent to the bottom of the multi-filmthermoplastic bag 700 a. In some implementations, the multiple areas ofcontact areas can be formed into patterns including alpha-numericcharacters (e.g., text). For example, as further shown in FIG. 8 , thecontact areas 728 are formed into words (e.g., “GLAD”). In otherimplementations, the multiple areas of contact areas can be formed intowords including brand names, claims, and instructions as describedabove.

As described above in relation to FIG. 4 , in order to form contactareas that are visible, a multi-film thermoplastic structure includes alighter colored film and a darker colored film. The bags 400, 600, 700,and 700 a provide the two layers in the form of a multi-filmthermoplastic bag. For example, the bags 400, 600, 700, and 700 acomprises a bag-in-bag configuration with an inner bag and an outer bag.Alternatively, the bags 400, 600, 700, and 700 a can comprise multi-filmsidewalls with each sidewall comprising an inner film and an outer film.In still further implementations, the sidewalls can comprise more thantwo films. In still further implementations, a thermoplastic bag withcontact areas arranged into text includes a single film or layered bag.In such implementations, a film insert smaller than a sidewall issecured to a sidewall to allow for the formation of contact areas formedinto text.

For example, FIGS. 9A and 9B illustrates a single-film thermoplastic bag900 with contact areas 901 formed into text (e.g., GLAD in a repeatingpattern). In particular, the single-film thermoplastic bag 900 includesa first sidewall 902 comprising a single film and an opposing secondsidewall 904 comprising a single film. Each sidewall 902, 904 of thesingle-film thermoplastic bag 900 can comprise a hem seal 905 to form ahem 912 that holds a draw tape 914. The hem seal 905 of each sidewall902, 904 can extend from a first side edge 906 to an opposing side edge908. Furthermore, side heat seals can run along the first and secondside edges 906, 908 to secure the first and second sidewalls 902, 904together.

As shown by FIGS. 9A and 9B, a strip of thermoplastic film 920 ispositioned within the single-film thermoplastic bag 900. The strip ofthermoplastic film 920 can comprise a second film in a multi-filmthermoplastic structure with contact areas arranged into text. Forexample, the strip of thermoplastic film 920 is bonded to the firstthermoplastic film sidewall 902 by the contact areas 901 arranged intotext. The difference in appearance of the strip of thermoplastic film920 compared to the single-film thermoplastic bag 900 can create thecontrast that allows the text created by the contact areas 901 to bevisible/legible as described above.

While FIGS. 9A-9B illustrate the strip of thermoplastic film 920 beingpositioned against both the first and second thermoplastic filmsidewalls 902, 904, in alternative implementations the strip ofthermoplastic film 920 is positioned against and bonded to only one ofthe first and second thermoplastic film sidewalls 902, 904. Furthermore,while FIGS. 9A-9B illustrate the strip of thermoplastic film 920 beingpositioned near the bottom 910 of the single-film thermoplastic bag 900,in alternative implementations the strip of thermoplastic film 920 ispositioned in the middle, along the sides, in the grab zone, or anotherposition of the single-film thermoplastic bag 900.

In addition, one or more implementations, the thermoplastic material ofthe strip of thermoplastic film 920 is selected to be different from thethermoplastic material of the sidewalls of the bag 900. The differingmaterial properties of the various films of the multi-film thermoplasticstructures with contact areas formed into text provide the structureswith the functional benefits of the individual films in a manner thatthe weakest layer(s) does not dominate the overall structure. In otherwords, unlike co-extruded films, one or more implementations combinedifferent films in a manner (e.g., non-continuous bonding) that enablesthe strengths of each film to be utilized without having a weakness ofone film directly compromise another film.

One or more implementations include non-continuously laminated structureof thermoplastic films with unique combinations of functional benefitsfrom the individual thermoplastic-films. For example, one or moreimplementations combine individual films with differing materialcompositions and functional benefits. For example, a first film cancomprise one or more of the scuff resistance, toughness,stretch-ability, impact resistance, high tensile strength, etc., and asecond film non-continuously bonded to the first film can compriseanother of the scuff resistance, toughness, stretch-ability, impactresistance, high tensile strength, etc. Thus, multi-film thermoplasticstructures with contact areas formed into text can provide variedfunctional benefits typically non present in a single or co-extrudedfilm. Furthermore, one or more implementations comprise combinations offunctional benefits not feasible in co-extruded films due to thetendency of the differing material compositions of the layers to resistmelt bonding or otherwise make the films unsuitable for co-extrusion(e.g., differing shrink rates).

Still further, one or more implementations comprise multi-filmthermoplastic structures with contact areas formed into text withcombinations of functional benefits that are typically not possible in asingle film. In particular, one or more implementations comprisemulti-film thermoplastic structures with contact areas formed into textwith functional benefits that are typically trade-offs or otherwiseopposed. For example, one or more implementations comprise multi-filmthermoplastic structures with contact areas formed into text with bothscuff resistance and high tensile strength, with both stretch-abilityand high tensile strength, with both impact resistance and high tensilestrength, or with both tear resistance and high tensile strength.

Thus, the first and second thermoplastic film sidewalls 902, 904 and thestrip of thermoplastic film 920 can each comprise films of thermoplasticmaterial. In particular, first and second thermoplastic film sidewalls902, 904 and the strip of thermoplastic film 920 can comprise any of thethermoplastic materials described hereinabove, or combinations thereof.In one or more implementations, the first and second thermoplastic filmsidewalls 902, 904 can comprise the same thermoplastic material as stripof thermoplastic film 920. In alternative implementations, the strip ofthermoplastic film 920 can comprise a different thermoplastic materialthan the first and second thermoplastic film sidewalls 902, 904. Forexample, the material of the strip of thermoplastic film 920 may have ahigher tensile strength, tear resistance, puncture resistance,elasticity, and/or abrasion resistance than the material of the firstand second thermoplastic film sidewalls 902, 904. A strip ofthermoplastic film 920 made of stronger and/or tougher material may helpfurther protect the bag 100 against rupture and/or puncture.

As mentioned above, in at least one implementation, the contact areasbetween portions of thermoplastic film layers of a multi-filmthermoplastic structure are formed passing through contact rollers in aprocess that includes applying heat and pressure to the portions ofthermoplastic film layers. FIG. 10 includes a chart 1000 illustrating anoptimal amount of heat and pressure applied during the heat embossingprocess that results in preferred quality measures (e.g., visual orpattern, physicals, blocking, and holes) of the resulting multi-filmthermoplastic structure.

For example, as shown in FIG. 10 , as heat and pressure increase, thephysical properties of a multi-film thermoplastic structure indicated bythe curve 1002 remain the same until a drop off point 1010 a (e.g.,yield point). After the drop off point 1010 a, the continued increase ofheat and pressure cause the physical properties of the multi-filmthermoplastic structure to deteriorate rapidly. As used herein, the“physical properties,” “physical parameters,” or “physicals” of amulti-film thermoplastic structure refer to the molecular strength ofthe multi-film thermoplastic structure. In particular, the physicalsindicated by curve 1002 can comprise transverse direction tensilestrength, transverse or machine direction tear resistance, or punctureresistance (e.g., as measured by a dart drop test).

As further shown in FIG. 10 , as heat and pressure increase in theprocess, the blocking of the multi-film thermoplastic structureindicated by the curve 1004 increases in approximately an exponentialmanner. As used herein, “blocking” refers to the level with which athermoplastic film sticks to itself. As indicated by the point 1010 b onthe curve 1012, there is an amount of heat and pressure beyond which theamount of blocking exhibited by a multi-film thermoplastic structure isundesirable. For example, a high level of blocking can cause themulti-film thermoplastic structure to self-stick in such a way that itis unusable for the processes described herein. In particular, by atleast point 1010 b the films are sealed together in a manner that theycannot be separated without causing the individual layers to fail.

Moreover, as shown in FIG. 10 , as heat and pressure increase in theheat embossing process, the aesthetic value (e.g., the visibility asmeasured by A E) of the pattern of heated pressure seals formed by theheat embossing process increases, as indicated by the curve 1006. Forexample, as indicated by the point 1010 c, an increasing amount of heatand pressure during the heat embossing process causes the aestheticvalue of the pattern of contact areas pressed into the multi-filmthermoplastic structure to increase to a desirable level. Below thiscritical level of energy at 110 c, the aesthetic value may result in apattern of contact areas that is difficult to recognize, unnuanced, orotherwise undesirable.

In one or more implementations, increasing heat and pressure during theheat embossing process also increases a flexural rigidity (or stiffness)of the multi-film thermoplastic structure. For example, flexuralrigidity refers to a measure of flexibility or rigidity of themulti-film thermoplastic structure. In at least one implementation, theflexural rigidity of the multi-film thermoplastic structure increases ina linearly proportional manner as heat and pressure increase in thecontact area formation process until a point where the rigidityplateaus. An increased amount of flexural rigidity in the multi-filmthermoplastic structure is desirable as it creates an increasedperception of strength and quality of the multi-film thermoplastic bagwhere the contact areas are incorporated. In one or moreimplementations, the contact areas can increase the flexural rigidity[microjoule/m] from 1.1 times to 5 times compared to a flat/undeformedfilm of the same gauge. More particularly, in one or moreimplementations, the contact areas can increase the flexural rigidityfrom 1.5 times to 4 times, or 1.5 times to 3 times, or 2 times to 4times compared to a flat/undeformed film of the same gauge.

Flexural rigidity of the multi-film thermoplastic structure can bemeasured according to a cantilever test and/or a heart loop test asdescribed in ASTM standard D1388-18. For example, the cantilever testmeasures flexural rigidity by sliding a strip of the multi-filmthermoplastic structure at a specified rate in a direction parallel toits long dimension, until a leading edge of the strip projects from theedge of a horizontal surface. The length of the overhang of the strip ismeasured when the end of the strip is depressed under its own mass tothe point where end of the strip droops by at least a 41.5 degree anglefrom the horizontal. The flexural rigidity of the multi-filmthermoplastic structure is determined based on the length of theoverhang. The heart loop test measures flexural rigidity by forming astrip of the multi-film thermoplastic structure into a heart-shapedloop. The length of the loop is measured when it is hanging verticallyunder its own mass. The flexural rigidity of the multi-filmthermoplastic structure is determined based on the length of the loop.Additionally, as shown in FIG. 10 , increasing heat and pressure cancause a creation of holes (e.g., micro pores or larger holes) within amulti-film thermoplastic structure. As illustrated, it is possible forthe process to create holes in the multi-film thermoplastic structureprior to any significant loss of other physicals (e.g., the molecularstrength of the multi-film thermoplastic structure). For example, anamount of heat and pressure beyond the point 1010 d can cause holes toform within one or more layers of the multi-film thermoplasticstructure. Holes within the multi-film thermoplastic structure aregenerally undesirable as they may make the multi-film thermoplasticstructure unfit for its intended purpose (e.g., lead to leaks in a trashbag).

Thus, as shown by the arrow 1008 in the chart 1000, there is a range ofheat and pressure that can be applied during the contact area creationprocess that results in optimized levels for physicals, blocking,pattern (i.e., visual), flexural rigidity, and holes. In one or moreimplementations, this range includes heating at least one contact rollerto a range of 125-325 degrees Fahrenheit. Furthermore, the rangeincludes pressure in the tooling nip at a range of 100-1100 pounds persquare inch. Moreover, in at least one implementation, the range alsoincludes speeds of the contact rollers at a range of 500-1200 feet perminute. In alternative implementations, the preferred range may includeheats, pressures, or speeds at other ranges.

When operated within the ranges of heat and pressure indicated by thearrow 1008 in the chart 1000, the contact areas creation processdescribed herein produces contact areas with optimized qualities. Forexample, in at least one embodiment, a contact area created by theprocess operating within the optimal heat and pressure ranges exhibits apattern where the Delta E of the pattern versus separated areas of thefilms is 0.3 to 50 points higher and more specifically 1.0 to 10.3points higher. For example, Delta E can refer to the visibility of thecontact area and can include one or more of a change in L luminancevalue associated with the contact area, a change in a-measure ofred/green lightness/darkness associated with the contact area, or achange in a b-measure of blue/yellow lightness/darkness associated withthe contact area. In one or more implementations, a contact area createdby the process operating within the optimal heat and pressure rangeindicated by the arrow 1008 exhibits a pattern where the Delta E of thepattern versus adjacent separated areas of film is 3.1 points higher onaverage.

Similarly, in at least one embodiment, a contact area created by theprocess operating within the optimal heat and pressure range indicatedby the arrow 1008 exhibits physicals where the peak load ratio of theareas including the contact area is between 38% and 100% of the TDtensile strength the films prior to formation of the contact area whenmeasured on a one-inch TD tensile pull test. More specifically thecontact area is between 54% and 100% of the TD tensile strength thefilms prior to formation of the contact area. In one or moreimplementations, a contact area created by the process operating withinthe optimal heat and pressure range indicated by the arrow 1008 exhibitsphysicals where the peak load ratio of the contact area is 92% of the TDtensile strength of the pre-processed film. In at least one embodiment,the contact area created by the process operating within the optimalheat and pressure range indicated by the arrow 1008 can also exhibitdesired levels of puncture resistance and tear values (in the machineand/or transverse direction).

Moreover, in at least one embodiment, a contact area created by theprocess operating within the optimal heat and pressure range indicatedby the arrow 1008 exhibits blocking where the peel strength [g/mm] isbetween 0.00 and 5.20, between 0.00 and 2.60, between 0.00 and 1.70, orbetween 0.00 and 0.88 when peel forces are exerted on a three-inch Tpeel between inner bag layers. Specifically, a contact area created bythe process operating with the optimal heat and pressure ranges exhibitsblocking where the peel strength [g/mm] is 0.29 when peel forces areexerted on a three-inch T peel between inner bag layers. Additionally,in at least one implementation, the contact areas are configured toseparate before any layer of the multi-film film or bag fails whensubjected to peel forces.

Additionally, as shown in FIG. 10 , a contact area created by theprocess operating within the optimal heat and pressure range indicatedby the arrow 1008 also exhibits minimal holes. For example, in at leastone embodiment, holes may be identified by inflating the multi-filmthermoplastic structure including the contact area and checking forlight show-through. Holes and blocking associated with multi-filmthermoplastic structure may be minimized while maximizing visual andphysicals by operating the process within the heat and pressure rangeindicated by the arrow 1008.

To produce a bag having one or more contact areas arranged into text asdescribed, continuous webs of thermoplastic material may be processedthrough a high-speed manufacturing environment such as that illustratedin FIG. 11 . In the illustrated process 1100, production may begin byunwinding a first continuous web or film 1180 of thermoplastic sheetmaterial from a roll 1104 and advancing the web along a machinedirection 1106. The unwound web 1180 may have a width 1108 that may beperpendicular to the machine direction 1106, as measured between a firstedge 1110 and an opposite second edge 1112. The unwound web 1180 mayhave an initial average thickness 1160 measured between a first surface1116 and a second surface 1118. In other manufacturing environments, theweb 1180 may be provided in other forms or even extruded directly from athermoplastic forming process.

In some implementations, the illustrated process 1100 involves unwindinga second continuous web or film 1182 of thermoplastic sheet materialfrom a roll 1102 and advancing the web along a machine direction 1106.The second film 1182 can comprise a thermoplastic material, a width,and/or a thickness that is similar or the same as the first film 1180.In alternative one or more implementations, one or more of thethermoplastic material, width, and/or thickness of the second film 1182can differ from that of the first film 1180. To provide the first andsecond sidewalls of the finished bag, the films 1180, 1182 may be foldedinto a first half 1122 and an opposing second half 1124 about themachine direction 1106 by a folding operation 1120. When so folded, thefirst edge 1110 may be moved adjacent to the second edge 1112 of theweb. Accordingly, the width of the films 1180, 1182 proceeding in themachine direction 1106 after the folding operation 1120 may be a width1128 that may be half the initial width 1108. As may be appreciated, theportion mid-width of the unwound films 1180, 1182 may become the outeredge of the folded films 1180, 1182. In any event, a hem channel may beformed by folding adjacent first and second edges 1110, 1112 over (e.g.,at a top edge) and a draw tape 1132 may be inserted into the hem channelduring a hem channel and draw tape operation 1130. In someimplementations, as shown in FIG. 11 , the hem channel and draw tapeoperation 1130 may fold over a length of the first and second edges1110, 1112 such that a hem skirt is formed (e.g., indicated by thedashed line following the operation 1130) down an inner surface of themulti-film thermoplastic bag.

To form one or more regions of contact areas arranged into text in amulti-film thermoplastic bag, the processing equipment may include atleast one set of contact rollers 1143 where at least one of the rolls isheated, such as those described herein above. Referring to FIG. 11 , thefolded web 1180 may be advanced along the machine direction 1106 betweenintermeshing rollers 1143 a, which impart contact areas 1150 arrangedinto text in one portion, zone, area, or section of the resultingmulti-film thermoplastic bag.

The folded web 1180 may then advance through the contact rollers 1143 b,which impart the contact areas 1150 to the resulting multi-filmthermoplastic bag. In one or more implementations, passing the foldedweb 1180 between the set of heated contact rollers 1143 b creates one ormore contact areas between flat portions of the folded web 1180 and thehem skirt (e.g., indicated by the dashed line). For example, the one ormore contact areas can extend from the hem channel over the hem skirttoward the bottom edge of the folded web 1180.

As mentioned above, in one or more implementations, one of the contactrollers 1143 b is heated (e.g., a metal contact roller) while othercontact roller is unheated (e.g., a rubber contact roller). In suchimplementations, having heat being applied to the one side of the films1180, 1182 can cause the contact areas on that heated side be morevisually distinct (e.g., darker) and/or have more blocking between thelayers on the headed side. Additionally, or alternatively, both of therollers 1143 a, 1143 b may be heated rollers. For example, each of therollers 1143 a, 1143 b may include a rubber roller (e.g., as a top orbottom roller) and a patterned roller.

In at least one embodiment, the processing equipment may include avision system or sensor system in connection with one or more of theintermeshing rollers 1143 a and the contact rollers 1143 b. For example,the vision system or sensor system may detect pattern presence,placements, and darkness. Similarly, the sensor system may detect the TDplacement of the film (e.g., similar to web breakout or guidingsystems). Additionally, the processing equipment may include a forcegauge probe to measure the drag of the film across the gauge betweeninner layers.

To avert imparting a pattern (e.g., of contact areas or otherwise) ontothe portion of the web that includes the draw tape 1132, thecorresponding ends of the rollers 1143 a, 1143 b may be smooth andwithout ridges, grooves, punch elements, or die elements. Thus, theadjacent edges 1110, 1112 and the corresponding portion of the webproximate those edges that pass between the smooth ends of the rollers1143 a, 1143 b may not be imparted with any pattern. In alternativeimplementations, the intermeshing rollers (if present) and the contactrollers are positioned prior to the drawtape insertion process.

The processing equipment may include pinch rollers 1162, 1164 toaccommodate the width 1158 of the web 1180. In one or moreimplementations, the nip rollers can be modified into contact rollers toproduce contact areas. For example, in implementations with continuouscontact areas, at least one of the pinch rollers 1162, 1164 can beheated and act as contact rollers.

In one more implementations, the heat and pressure of the contactrollers can ensure that there is little to no bonding between the foldedhalves 1122, 1124 to ensure that the bag 1184 can be opened.

To produce the finished bag, the processing equipment may furtherprocess the folded web with at least one region of contact areas. Forexample, to form the parallel side edges of the finished multi-filmthermoplastic bag, the web may proceed through a sealing operation 1170in which heat seals 1172 may be formed between the folded edge 1126 andthe adjacent edges 1110, 1112. The heat seals may fuse together theadjacent halves 1122, 1124 of the folded web. The heat seals 1172 may bespaced apart along the folded web and in conjunction with the foldedouter edge 1126 may define individual bags. The heat seals may be madewith a heating device, such as, a heated knife. A perforating operation1181 may perforate the heat seals 1172 with a perforating device, suchas, a perforating knife so that individual bags 1192 may be separatedfrom the web. In one or more implementations, the webs may be folded oneor more times before the folded webs may be directed through theperforating operation. The web 1180 embodying the bags 1184 may be woundinto a roll 1186 for packaging and distribution. For example, the roll1186 may be placed in a box or a bag for sale to a customer.

In one or more implementations of the process, a cutting operation 1188may replace the perforating operation 1180. The web is directed througha cutting operation 1188 which cuts the webs at location 1190 intoindividual bags 1192 prior to winding onto a roll 1194 for packaging anddistribution. For example, the roll 1194 may be placed in a box or bagfor sale to a customer. The bags may be interleaved prior to windinginto the roll 1194. In one or more implementations, the web may befolded one or more times before the folded web is cut into individualbags 1192. In one or more implementations, the bags 1192 may bepositioned in a box or bag, and not onto the roll 1194.

The present disclosure may be embodied in other specific forms withoutdeparting from its spirit or essential characteristics. Thus, thedescribed implementations are to be considered in all respects only asillustrative and not restrictive. The scope of the disclosure is,therefore, indicated by the appended claims rather than by the foregoingdescription. All changes that come within the meaning and range ofequivalency of the claims are to be embraced within their scope.

We claim:
 1. A multi-film thermoplastic structure comprising: a firstthermoplastic film having a first appearance; a second thermoplasticfilm having a second appearance created by a pigment, the firstappearance differing from the second appearance; one or more separatedportions where the first thermoplastic film and the second thermoplasticfilm are not in intimate contact; and one or more contact areas arrangedinto text, wherein the one or more contact areas arranged into textcomprise: portions of the multi-film thermoplastic structure where thefirst thermoplastic film and the second thermoplastic film are inintimate contact; and a contrast relative to separated portionssurrounding the one or more contact areas, which when viewed in thefirst thermoplastic film makes the text legible, wherein the contrast isdue to a difference in Delta E of 5 to 15 points between the one or morecontact areas arranged into text and the separated portions surroundingthe one or more contact areas.
 2. The multi-film thermoplastic structureas recited in claim 1, wherein the one or more contact areas arrangedinto text comprise the second appearance.
 3. The multi-filmthermoplastic structure as recited in claim 2, wherein the one or moreseparated portions have a third appearance differing from the firstappearance and the second appearance.
 4. The multi-film thermoplasticstructure as recited in claim 3, wherein: the first appearance is afirst color due to a first pigment in the first thermoplastic film; thesecond appearance is a second color due to the pigment in the secondthermoplastic film; the third appearance is a third color; and themulti-film thermoplastic structure is devoid of a pigment of the thirdcolor.
 5. The multi-film thermoplastic structure as recited in claim 1,wherein the one or more contact areas arranged into text have physicalparameters that are substantially equal to physical parameters of themulti-film thermoplastic structure in the one or more separatedportions.
 6. The multi-film thermoplastic structure as recited in claim1, wherein the one or more contact areas arranged into text form bondsbetween the first thermoplastic film and the second thermoplastic film.7. The multi-film thermoplastic structure as recited in claim 6, whereinthe bonds of the one or more contact areas arranged into text areconfigured to separate before either of the first thermoplastic film orthe second thermoplastic film fails when subjected to peel forces. 8.The multi-film thermoplastic structure as recited in claim 6, whereinthe bonds of the one or more contact areas arranged into text are notconfigured to separate before either of the first thermoplastic film orthe second thermoplastic film fails when subjected to peel forces. 9.The multi-film thermoplastic structure as recited in claim 1, whereinthe text comprises a suffocation warning.
 10. A thermoplastic bagcomprising: first and second thermoplastic film sidewalls joinedtogether along a first side edge, an opposite second side edge, and aclosed bottom edge, wherein the first and second thermoplastic filmsidewalls comprise a first color; a layer of thermoplastic materialadjacent to at least a portion of the first thermoplastic film sidewall,wherein the layer of thermoplastic material comprises a second color;one or more separated portions where the first thermoplastic filmsidewall and layer of thermoplastic material are separated by a gap; andone or more contact areas arranged into text, wherein the one or morecontact areas arranged into text comprise: portions in which the firstthermoplastic film sidewall and layer of thermoplastic material arebonded together; and the second color whereby the one or more contactareas arranged into text differ in appearance from separated portionssurrounding the one or more contact areas making the text legible whenviewed in the first thermoplastic film sidewall due to a difference inDelta E of 5 to 15 points between the one or more contact areas arrangedinto text and the one or more separated portions.
 11. The thermoplasticbag as recited in claim 10, wherein the layer of thermoplastic materialcomprises a strip of thermoplastic material bonded to the firstthermoplastic film sidewall by the one or more contact areas arrangedinto text.
 12. The thermoplastic bag as recited in claim 10, wherein thelayer of thermoplastic material comprises a third sidewall of an innerthermoplastic bag positioned within the thermoplastic bag, the innerthermoplastic bag further comprising a fourth sidewall joined to thethird sidewall along a side edge, an opposing side edge, and a secondbottom.
 13. The thermoplastic bag as recited in claim 12, furthercomprising heat seals securing the thermoplastic bag to the innerthermoplastic bag, wherein the heat seals in the thermoplastic bag havethe second color and are not configured to separate before either of thethermoplastic bag or the inner thermoplastic bag fails when subjected topeel forces.
 14. The thermoplastic bag as recited in claim 10, whereinthe one or more contact areas arranged into text extend across a widthof the thermoplastic bag from the first side edge toward the oppositesecond side edge.
 15. The thermoplastic bag as recited in claim 10,wherein the one or more contact areas arranged into text extend across aheight of the thermoplastic bag from the closed bottom edge toward anopening of the thermoplastic bag.
 16. The thermoplastic bag as recitedin claim 10, wherein the one or more contact areas arranged into textare less visible when viewed in the layer of thermoplastic material ofthe second color than when viewed in the first thermoplastic filmsidewall of the first color.
 17. The thermoplastic bag as recited inclaim 10, wherein: the first color comprises a light color; the secondcolor comprises a dark color; and the one or more contact areas whenviewed in the layer of thermoplastic material have an appearance similarto the separated portions surrounding the one or more contact areasmaking text less legible than when viewed in the first thermoplasticfilm sidewall.